Dodge - Neon - Workshop Manual - 1995 - 1995

Factory Workshop Manual Make Dodge Model Neon Engine and year L4-2.0L SOHC (1995) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The relay box is mounted on the Hydraulic Control Unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7 ABS Main Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 8 ABS Main Relay: Description and Operation ABS SYSTEM RELAY The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the control module. Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the left headlamp ground. When the system is operating normally, power for the contact side of the relay is supplied from the control module on the B47 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F18 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: Customer Interest ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: All Technical Service Bulletins ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 25 ABS Control Module: Locations ABS Controller The controller is located in the passenger compartment, on the left kick panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 26 Controller Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 27 ABS Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 28 ABS Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 38 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 39 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 45 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 46 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 50 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 51 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 62 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 63 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 65 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 68 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Radiator Fan Relay: Connector Views Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Air Conditioning-Heater (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Air Conditioning-Heater (Part 2 Of 2) The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 76 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Control Relay Circuit NAME OF CODE: High Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the high speed radiator fan relay control circuit. THEORY OF OPERATION: The high speed radiator fan relay controls the high speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Low Speed Fan Control Relay Circuit NAME OF CODE: Low Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the low speed radiator fan relay control circuit. THEORY OF OPERATION: The low speed radiator fan relay controls the low speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Rad Fan Control Relay Circuit NAME OF CODE: Rad Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 77 SET CONDITION: An open or shorted condition is detected in the radiator fan relay control circuit. THEORY OF OPERATION: The radiator fan relay controls the operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. When the engine coolant temperature has reached the maximum temperature parameter, the relay will be grounded. Conversely, when the engine coolant temperature has acquired the minimum temperature parameter, the relay will remove the ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Low speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Fan Relay: Initial Inspection and Diagnostic Overview - Check the 30 Amp maxi fuse located in the Power Distribution center (PDC) for the radiator fan motor(s). - Check the 15 Amp fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor clutch relays. - Check the 10 Amp micro fuse located in the power distribution center. When checking the A/C compressor clutch relay, - Check the 25 Amp fuse located in cavity 7 of the fuse block when checking blower motor operation, - Check the right headlamp ground located at the right fender side shield. - Check the left headlamp ground located on the left side of the radiator closure panel. - On vehicles equipped with A/C, check the refrigerant level. The system will not operate with a low level of refrigerant. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Relay > Component Information > Description and Operation Cruise Control Relay: Description and Operation NAME OF CODE: Speed Control Power Relay Circuit WHEN MONITORED: With the ignition key ON, speed control switched ON, the SET button pressed and the brake pedal released. SET CONDITION: The speed control power supply circuit is either open or shorted to ground. THEORY OF OPERATION: The PCM monitors the voltage drop across all speed control solenoids and the power supply circuit. POSSIBLE CAUSES: - PCM misfire - Open or shorted power supply circuit - Failed dump solenoid (S/C servo) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 91 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 92 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 93 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Relays and Modules - Cooling System/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation DAYTIME RUNNING LAMP (DRL) MODULE - CANADIAN VEHICLES ONLY On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position, and the parking brake switch is open. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 amp maxi fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block that feeds circuit G5 through a 5 amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G5 connects to cavity 1 of the DRL module. Circuit G9 connects to cavity 3 of the DRL module. The G9 circuit splices to the brake warning switch, park brake switch, and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the Power Distribution Center feeds circuit L20. Circuit L20 connects to cavity 6 of the DRL module connector. A 40 amp maxi fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the lowbeams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit L4 originates at cavity 4 of the multi-function switch. The L4 circuit splices to cavity 10 of the DRL module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 106 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 107 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 108 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 109 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 111 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 112 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 113 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 114 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 115 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 116 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: Recalls Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: Recalls Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 131 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 132 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 133 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 139 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 140 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: Customer Interest PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 145 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 150 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 156 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 157 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder > Page 162 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set > Page 167 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 176 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 177 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 178 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 184 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 185 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder > Page 190 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 195 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 205 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 206 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 207 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 208 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 209 Fig. 2 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 213 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 214 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 218 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 220 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 221 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 222 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 223 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 226 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 228 Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Powertrain Control Module: Electrical Diagrams Wiring Diagrams For Information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams 5 Volt Supply Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 230 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation Powertrain Control Module: Description and Operation PCM Operation Fig. 2 Powertrain Control Module (PCM) Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 233 - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 234 Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 235 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Battery Feed Operation BATTERY FEED Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 11 of the powertrain control module (PCM). A 20 amp micro fuse in the PDC protects circuit A14. Internal Controller Failure NAME OF CODE: Internal Controller Failure WHEN MONITORED: With the ignition ON. SET CONDITION: There is an Eraseable Programable Read Only Memory (EPROM) sum check failure at power down. THEORY OF OPERATION: This code indicates the EPROM memory may be corrupt. POSSIBLE CAUSES: - Failed Powertrain Control Module (PCM) PCM Failure EEPROM Write Denied NAME OF CODE: PCM Failure EEPROM Write Denied WHEN MONITORED: With the ignition ON, SBEC tries to write to EEPROM memory. SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus PCM Failure SPI Communications NAME OF CODE: PCM Failure SPI Communications WHEN MONITORED: With the ignition ON. SET CONDITION: Serial communications inside the controller fail eight times during a run cycle. THEORY OF OPERATION: Communications between microprocessors inside the Powertrain Control Module (PCM) are needed to operate the total system. If failure occurs, the solenoids and relays may not actuate properly. POSSIBLE CAUSES: - PCM failure PCM Failure SRI Mile Not Stored NAME OF CODE: PCM Failure SRI Mile Not Stored WHEN MONITORED: With the ignition ON SBEC tries to write service reminder indicator mileage to EEPROM memory. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 236 SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus 5 Volt Supply Output Too Low NAME OF CODE: 5 Volt supply Output Too Low WHEN MONITORED: With the ignition ON. SET CONDITION: The 5 volt supply to the sensors is below 3.5 volts for 4 seconds. THEORY OF OPERATION: The PCM maintains a 5 volt supply to the MAP sensor, Throttle Position (TP) sensor, and A/C pressure sensor. It is critical that the 5 volt supply stays between 4.8 and 5.1 volts as this input has a direct effect on sensor output voltages. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut-Down (ASD) relay and fuel pump relay. The A14 circuit also splices to the data link connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 239 Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) PCM 60 Way Connector Checks Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 240 Powertrain Control Module 60-Way Connector Check the powertrain control module (PCM) 60-way connector for: Spread terminals - Stretched or pulled out wires - Moisture or corrosion - Under-tightened or over-tightened 60 way connector Tighten the PCM connector to 4 Nm (35 in lb) torque. When checking terminal pinouts, refer to the Powertrain Control Module 60-Way Connector Diagram for circuit wire colors and cavity numbers. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 241 Powertrain Control Module: Service and Repair Fig. 21 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 21). REMOVAL 1. Disconnect negative cable from battery 2. Remove screws attaching PCM to body 3. Lift PCM up. Disconnect PCM 60-way connector. 4. Remove PCM. INSTALLATION 1. Attach 60-way connector to PCM. Tighten 60-way connector screw to 4.5 Nm (40 in lb) torque. 2. Install PCM. Tighten mounting screws to 9 Nm (80 in lb) torque. 3. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 249 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 250 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 255 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 256 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 258 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 261 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 266 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 267 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 268 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 269 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel pump relay is located in the power distribution center, at the lefthand side of the engine compartment and behind the battery. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 278 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 284 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 285 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 287 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 290 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Fuel Pump Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 293 Fuel Pump Relay: Description and Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 294 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 295 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 303 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 309 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 310 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 312 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 313 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 315 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 320 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 321 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 322 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 323 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations > Page 328 Air Bag Control Module Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 331 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 332 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 333 Supplemental Restraint System (SRS) Control Module: Description and Operation Fig. 3 Passenger Airbag OPERATION The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM will store sufficient energy to deploy the airbags for at least one second after the battery is disconnected. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for six to eight seconds every time the vehicle is started. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage - to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the fuse block bus bar that feeds the F15 circuit. A 30 amp maxi fuse in the PDC protects the Al and A21 circuits. A 10 amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 30 amp maxi fuse in the PDC protects the A2 and A22 circuits. A 10 amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 334 Supplemental Restraint System (SRS) Control Module: Testing and Inspection - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 335 Supplemental Restraint System (SRS) Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Automatic transaxle only, remove shifter knob fastener and remove shifter knob. 3. Remove attaching screw from each of the two forward cup holders of the floor console. Remove screws at the rear of the console or with armrest inside of console bin. 4. Pull park brake lever all the way up. Fig. 12 Airbag Control Module 5. Lift the floor console at the rear and guide it out from under the instrument panel. 6. Remove module mounting nuts and remove module. Fig. 13 Airbag Control Module 7. Disconnect ACM 4-way and 13-way connectors. INSTALLATION 1. Connect ACM both connectors and ensure both connectors and all locking tabs are engaged. CAUTION: Use supplied screws only. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 336 3. Install floor console into position. 4. Install attaching screw in each of the two forward cup holders. 5. Install screws at the rear of the console or with armrest inside of console shifter bezel with screw located in ash receiver. 6. Replace shifter knob and fastener. 7. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 352 39 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 353 43 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 354 45 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 355 47 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 356 51 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 357 55 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 358 57 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 359 59 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 360 63 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 361 67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 362 69 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 363 71 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 364 173 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 365 177 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 366 179 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 367 181 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 368 187 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 369 191 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 370 193 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 371 195 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 372 201 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 373 205 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 374 207 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 375 209 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 376 256 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel Speed Sensors 1800 - 2600 ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 379 Wheel Speed Sensor: Mechanical Specifications Wheel Speed Sensor/Tone Wheel Air Gap 0.04 - 1.67 mm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Wheel Speed Sensor: Locations Front Wheel Speed Sensors Wheel Speed Sensor The front wheel speed sensors are located on the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 382 Wheel Speed Sensor: Locations Rear Wheel Speed Sensors Wheel Speed Sensor The rear wheel speed sensors are located on the rear brake support plate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 385 Wheel Speed Sensor: Diagrams Rear Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 386 Wheel Speed Sensor: Description and Operation One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 387 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 397 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 403 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 409 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 410 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 411 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 412 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 417 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 423 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 424 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 426 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 429 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 434 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 437 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 438 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 443 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High Cruise Control Switch: Description and Operation Speed Control Switch Always High NAME OF CODE: Speed Control Switch Always High WHEN MONITORED: With the ignition key ON. SET CONDITION: An open condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. POSSIBLE CAUSES: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High > Page 448 Cruise Control Switch: Description and Operation Speed Control Switch Always Low NAME OF CODE: Speed Control Switch Always Low WHEN MONITORED: With the ignition key ON. SET CONDITION: A shorted condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is below 0.7 volts for more than 2 minutes. POSSIBLE CAUSES: - Mux switch circuit shorted to ground - Switch failure - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 449 Cruise Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 450 Cruise Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 463 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 464 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 465 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 466 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 467 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 468 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 469 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 470 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 471 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 472 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 473 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 474 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 475 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 476 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 477 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 21°C (70°F) and 32°C (90°F) when testing the switch. 1. Disconnect the 3-wire connector from switch lead located behind the glove box. Fig. 2 Fin-sensing Cycling Clutch Switch Harness Connector 16 2. Test for voltage between pin #1 to pin #3 on the wire harness connector. If voltage is detected, jump pin #1 to pin #3 using a jumper wire. Compressor clutch should engage. 3. Check for voltage between pin #1 and pin #2. If no voltage is detected, check fuse and ground circuit. 4. If compressor clutch engages, test for continuity from terminal pin #1 to pin #3 of the switch lead connector. Continuity should be detected. If not, replace the Fin-sensing Cycling Clutch Switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 478 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 488 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 494 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 498 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 499 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 503 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 504 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 505 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 518 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition > Page 523 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 529 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 534 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: Customer Interest Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 548 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 553 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 556 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 557 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 558 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 559 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 560 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 561 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 562 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 565 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 566 Fuel Tank Sending Unit Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation Fuel Gauge Sender: Description and Operation Fuel Level Sensor Operation FUEL LEVEL SENSOR Circuit G4 connects the fuel-level sensor to the fuel gauge in the instrument cluster, and splices to the Powertrain Control Module (PCM). The fuel-level sensor is a variable resistor. Circuit G5 from the fuse block supplies voltage to the fuel gauge. The fuel-level sensor draws voltage from circuit G5 through the fuel gauge on circuit G4. Circuit Z2 provides the ground path for the fuel-level sensor. The grounding point for circuit Z2 is the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 569 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too High NAME OF CODE: Fuel Level Sending Unit Volts Too High WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes above a calculated value. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating a low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 570 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too Low NAME OF CODE: Fuel Level Sending Unit Volts Too Low WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes below 0.75 volt. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low speeds. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 571 Fuel Gauge Sender: Description and Operation Fuel Level Unit No Change Over Miles NAME OF CODE: Fuel Level Unit No Change Over Miles WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 does not change a calibrated amount over a calculated number of miles. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration Fuel Gauge Sender: Testing and Inspection Test For Sending Unit Opration Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 574 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 575 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Helpful Information Gas current flows through coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel-level sensor contains a variable resistor. As the position of the float arm on the fuel-level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. ^ Circuit G4 connects to cavity 13 of the Powertrain Control Module (PCM) connector. The PCM determines low fuel level from circuit G4. Refer to Group 14 for fuel system operation. ^ Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 10 of the PCM, and cavity 2 of the TPS connector. ^ The PCM provides a ground for the throttle position sensor signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 3 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 576 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Testing Fig. 6 Level Sensor Diagnosis OPERATION This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Refer to the electrical diagrams for circuit identification. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. PROCEDURE 1. Connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. 2. Move the float lever to the positions shown in the resistance chart. 3. Record the resistance at each point. - Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 577 Fuel Gauge Sender: Testing and Inspection Fuel Pump Module Helpful Information Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 578 Fuel Gauge Sender: Service and Repair Fig. 7 Fuel Pump/Level Sensor Electrical Connector REMOVAL 1. Remove fuel pump module. Refer to procedure. 2. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 8 Wire Terminal Locking Wedge 3. Pull off blue locking wedge. Fig. 9 Wire Terminal Locking Finger 4. Using a small screwdriver lift locking finger away from terminal and push terminal out 6f connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 579 Fig. 10 Removing Wires From Connector 5. Push level sensor signal and ground terminals out of the connector. Fig. 11 Loosening Level Sensor 6. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Fig. 12 Level Sensor Removal/Installation 7. Slide level sensor wires through opening fuel pump module. 8. Slide level sensor out of installation channel in module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 580 Fig. 13 Groove In Back Side Of Level Sensor INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. Fig. 14 Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN SWITCH The Key-IN chime is used to indicate to the operator that the key is in the ignition with the driver's door open. If the key is in the ignition and the driver's door is open, a ground path is completed from the G26 circuit at the cluster, through the closed Key-IN switch, to the G16 circuit, and terminating at the door ajar switch, which is case-grounded. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Backup Lamp Switch: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: Customer Interest M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backup Lamp Switch: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: All Technical Service Bulletins M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 598 Backup Lamp Switch: Description and Operation BACK-UP LAMP SWITCH On automatic transmissions, the back-up lamp switch is part of the PARK/NEUTRAL position switch. The back-up lamp switch does not connect to the Powertrain Control Module (PCM) on manual transaxle equipped vehicles. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 599 Backup Lamp Switch: Testing and Inspection In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 Amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 604 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 605 Stop Lamp Switch: Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 606 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: Customer Interest Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 615 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: All Technical Service Bulletins Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 621 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 630 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition > Page 635 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 641 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 646 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 amp maxi fuse protects the A3 circuit. The headlamp switch has an internal 24 amp circuit breaker that connects circuit A3 to either the L2 or L20 circuit, depending on switch position. In the OFF and PARK positions, cavity 7 of the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the head-lamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 651 Headlamp Switch: Description and Operation Headlamp Switch In ON Position HEADLAMP SWITCH IN ON POSITION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low-beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in the fuse block, and power the low-beam headlamps. Circuit L43 supplies current to the left headlamp. Circuit L44 supplies current to the right headlamp. The L43 and L44 circuits each have separate 10 amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high-beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high-beam operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 652 Headlamp Switch: Testing and Inspection ^ Cavity 7 (circuit L20) of the headlamp switch connector is double-crimped to feed the Daytime Running Lamp (DRL) module. ^ Check for a blown fuse in cavity 17 for L43 and in cavity 18 for L44. ^ Check the 40 amp maxi fuse located in the Power Distribution Center (PDC). ^ The headlamp switch has a 24 amp internal circuit breaker. ^ For the left front parking lamp, turn signal, side marker lamp, and left headlamp, the Z1 circuit grounding point is on the left side of the radiator closure panel. ^ For the right front parking lamp, turn signal, side marker lamp, and right headlamp, the Z1 circuit grounding point is in the right fender side shield. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 653 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 662 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 668 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 678 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 679 Absolute Pressure Sensor: Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 683 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 686 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 695 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 696 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 701 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 707 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 718 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 719 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 720 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 723 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 724 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 725 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 730 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 731 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 732 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 733 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 736 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 738 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 744 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 745 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 747 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 750 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 755 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 758 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 759 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 763 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 768 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 774 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 775 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 785 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 786 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 787 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 788 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 789 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 792 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 793 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor Torque ....................................................................................................................................................... 10 Nm (90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 797 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 801 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 802 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 804 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 806 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 808 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 809 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 811 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 812 Intake Air Temperature Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 814 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 815 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 816 Intake Air Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor-PCM Input Fig. 4 Intake Air Temperature Sensor And MAP Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the intake air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse width and spark advance. The IAT sensor threads into the intake manifold (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 819 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation Fig. 16 Intake Air Temperature Sensor And MAP Sensor PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 6 of the PCM, and cavity 1 of the sensor connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 820 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High NAME OF CODE: Intake Air Temp Sensor Voltage High WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes above 4.9 volts. THEORY OF OPERATION: The Intake Air Temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 821 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low NAME OF CODE: Intake Air Temp Sensor Voltage Low WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes below 0.157 volt. THEORY OF OPERATION: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 824 Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 28 Intake Air Temperature Sensor 1. With the key off, disconnect wire harness connector from the intake air temperature sensor (Fig. 28). 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 6 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 825 Intake Air Temperature Sensor: Service and Repair Fig. 10 Intake Air Temperature Sensor And MAP Sensor NOTE: The intake air temperature sensor threads into the intake manifold plenum (Fig. 10). REMOVAL 1. Remove engine cover. 2. Disconnect electrical connector from sensor. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Install engine cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 829 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 834 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 840 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 841 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 843 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 846 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 849 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 852 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 857 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 858 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 863 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 869 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 870 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 871 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 872 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Manifold Pressure/Vacuum Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 875 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Manifold Absolute Pressure Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Operation Fig. 4 Intake Air Temperature Sensor And MAP Sensor The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately - As vacuum decreases, MAP sensor voltage increases proportionately Key ON At key ON -- during cranking, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. Engine Running While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP sensor mounts to the intake manifold (Fig. 4). CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 29 of the PCM, and cavity 3 of the MAP connector. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 880 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: The MAP sensor is a semiconductor type sensor. This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Signal circuit open - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM MAP Sensor Voltage Too Low NAME OF CODE: MAP Sensor Voltage Too Low WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The Manifold Absolute Pressure (MAP) sensor signal voltage is below 1.2 volts at start, or below 0.2 volt for 1.76 seconds with engine running. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - Failed PCM No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition ON and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 881 high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM No 5 Volts to MAP Sensor NAME OF CODE: No 5 Volts to MAP Sensor WHEN MONITORED: With the ignition OFF. SET CONDITION: The MAP sensor signal voltage goes below 1.96 volts. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5 volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. - The MAP receives a 5 volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - MAP sensor failure TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 884 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Refer to Group 14 for Manifold Absolute Pressure (MAP) sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 885 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 17 Intake Air Temperature Sensor And MAP Sensor NOTE: The MAP sensor attaches to the intake manifold plenum (Fig. 17). REMOVAL 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions Oxygen Sensor: Technical Service Bulletins Engine Controls/Electrical - Manual Revisions NUMBER: 08-32-94 GROUP: Electrical DATE: Jul. 15, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon Service Manual Supplement - Publication No. 81-270-5025A DESCRIPTION OF CHANGES O2 Sensor K42 Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 890 8W-30-16 Eliminate Alternate Cavity 15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 891 8W-80-8 Eliminate Alternate Cavity 2 On Connector C142 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 892 8W-80-15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 893 Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 896 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 897 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 902 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 908 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 909 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 910 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 911 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 914 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Oxygen Sensor: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Oxygen Sensors Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 917 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description Oxygen Sensor: Description and Operation Oxygen Sensor Description Downstream Oxygen Sensor Fig. 13 Downstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Upstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 920 Fig. 12 Upstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. OPERATION The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. - When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Heating Element The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. - Also, it allows the system to remain in closed loop operation during periods of extended idle. Closed Loop Operation In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. Open Loop Operation In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 921 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure NAME OF CODE: Downstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the PCM powers up the sensor heater. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Downstream O2 Sensor Shorted to Ground NAME OF CODE: Downstream O2S Shorted To Ground WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: The downstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage NAME OF CODE: Downstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The downstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 922 and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Downstream O2 Sensor Slow Response NAME OF CODE: Downstream O2 Sensor Slow Response WHEN MONITORED: With the vehicle engine temperature greater than 170° F and engine speed over 1,600 rpm. Rich response test is conducted when at WOT, with the front O2 sensor indicating a rich F/A condition. Lean response test is conducted when at closed throttle, in decel fuel shut-off (except SOHC automatic transmission vehicles), and with the front O2 sensor indicating a lean F/A condition. SET CONDITION: The rich response test will fail if the downstream O2 sensor voltage is less than 0.60 volts within 5 seconds of meeting the test conditions. The lean response test will fail if the downstream voltage is greater than 0.29 volts within 5 seconds of meeting the test conditions. The trouble code will be set if either (or both) tests fail three times per trip. Once the rich and lean response test each pass once, the testing is complete that trip. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Exhaust leak - Fuel contamination - Electrical wiring connectors - Engine mechanical Downstream O2 Sensor Stays at Center NAME OF CODE: Downstream O2 Sensor Stays at Center WHEN MONITORED: With the vehicle engine running for over 2 minutes, temperature greater than 170° F, in closed loop. SET CONDITION: With oxygen sensor voltage staying between 0.39 volts and 0.52 volts during the trip, the PCM pulls the sensor voltage to 5.0 volts for 30 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Sensor output wire open - Electrical wiring connectors - Open ground circuit - PCM failure - Oxygen sensor failure O2S Stays Above Center (Rich) NAME OF CODE: O2S Stays Above Center (Rich) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 923 WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays between 0.5 and 1.2 volts without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - High fuel pressure - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem O2S Stays Below Center (Lean) NAME OF CODE: O2S Stays Below Center (Lean) WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays below 0.5 without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Low fuel pressure - Vacuum Leak - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem Upstream O2 Sensor Heater Failure NAME OF CODE: Upstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the Powertrain Control Module (PCM) powers up the sensor heater. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 924 the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Upstream O2 Sensor Shorted to Ground NAME OF CODE: Upstream O2 Sensor Voltage Shorted to Ground WHEN MONITORED: With the ignition key off, after the engine cools down. SET CONDITION: The upstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals - Connector wires Upstream O2 Sensor Shorted to Voltage NAME OF CODE: Upstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The upstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The Powertrain Control Module (PCM) receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Upstream O2 Sensor Slow Response NAME OF CODE: Upstream O2S Response WHEN MONITORED: With the engine running for more than 3 minutes, engine temperature greater than 170° F, after reaching a vehicle speed of 24 MPH, at idle with Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 925 the transmission in drive (auto) or in neutral (manual). SET CONDITION: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300-350° C (572-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. POSSIBLE CAUSES: - Exhaust leak - Fuel contamination Upstream O2 Sensor Stays at Center NAME OF CODE: Upstream O2S Stays at Center WHEN MONITORED: With the engine running for more than 2 minutes and engine temperature greater than 170° F. SET CONDITION: The upstream oxygen sensor signal voltage is 0.5 volts for 1.5 minutes. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire open - O2 sensor failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 926 Oxygen Sensor: Testing and Inspection NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 929 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 930 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 939 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 945 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 950 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 951 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 952 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 953 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 958 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 959 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 960 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 961 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 967 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 968 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 969 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 970 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 975 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 976 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 977 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 978 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 981 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 982 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 986 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 987 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 993 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 994 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 996 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 997 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 999 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 1004 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 1013 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 1019 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1022 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1023 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1026 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1027 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1028 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1029 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1030 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1031 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1035 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1036 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1041 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1042 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 1045 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 1046 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1049 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 1050 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 1051 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1073 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 1084 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 1090 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 1091 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Vehicle Speed Sensor: Electrical Diagrams Complete System Diagram For wiring Diagrams, refer to Powertrain Management/Diagrams/Electrical. See: Powertrain Management/Diagrams/Electrical Diagrams Vehicle Speed Sensor Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 180°F. SET CONDITION: No signal from the vehicle speed sensor (TCM) is present for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor is a hall effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. - The PCM supplies 8 volts from cavity 44 to power up the sensor. - Sensor ground is supplied by PCM cavity 51. - The PCM also supplies a 5.0 volt pull up voltage to the sensor from cavity 5. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion damaged - Open 8 volt supply circuit - Open sensor circuit ground - Failed speed sensor - PCM failure - Connector Terminals/Wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal > Page 1113 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 1114 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 1115 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 7 Nm (60 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 1125 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 1131 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1134 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1135 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 1157 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 1158 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1161 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 1162 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 1163 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1171 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1172 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1194 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1195 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1196 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1199 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1200 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 1201 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1205 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 1227 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 1228 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 1229 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 1230 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 1231 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 1234 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1235 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 1240 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1241 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1242 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 1246 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 1266 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 1269 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1275 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1276 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1277 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1278 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1279 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1280 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1281 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1282 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1283 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1284 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1285 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1286 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1287 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 1292 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 1295 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation AIRBAG IMPACT SENSORS Two airbag impact sensors provide input to the Air-bag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connector. Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 1298 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Page 1299 Impact Sensor: Testing and Inspection Helpful Information - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 1302 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 1303 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 1304 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1309 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 1312 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 1322 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 1323 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 1324 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation Neutral Safety Switch: Description and Operation NAME OF CODE: Park/neutral Switch Failure WHEN MONITORED: with the transmission in park, neutral, or drive, and the transmission not in limp-in mode. SET CONDITION: If the transmision is in park or neutral, the engine must be cranking. If the transmission is in drive, the vehicle speed must be above 50 mph, the engine speed must be between 1,985 and 4,480 rpm, the TP sensor must not be closed, and the MAP must be above 66% of barometric pressure. THEORY OF OPERATION: The park/neutral position switch is used to communicate the state of the transmission to the idle air control (IAC) motor via the PCM. The IAC motor needs this information in order to determine the target idle speed. The IAC motor holds the idle speed at 600 rpm in park or neutral, while it increases the engine speed to about 800 rpm when the transmission is shifted into drive. Spark also is advanced in park or neutral position, while it is retarded in drive position. POSSIBLE CAUSES: - Dirty or melted connector contacts - Disconnected wiring harness - Park/neutral position switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 1338 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 1344 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 1349 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 1350 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 1351 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 1352 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1357 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1358 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1359 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1360 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 1366 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 1367 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 1368 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 1369 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1374 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1375 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1376 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 1377 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 1380 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 1381 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 1403 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1427 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Customer Interest for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: Customer Interest Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: All Technical Service Bulletins Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Page 1444 Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Page 1445 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove three screws from steering column shroud and remove upper half of shroud. 3. Remove mounting screws on switch and remove switch. 4. Disconnect electrical connector from switch. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 1455 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 1456 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 1462 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 1463 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 1468 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020694 > Jul > 94 > Alignment Specification - Revisions Alignment: All Technical Service Bulletins Alignment Specification - Revisions NO: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 SUBJECT: Service Manual Revision - Alignment Specifications MODELS: 1995 (PL) Neon DISCUSSION: This technical service bulletin references revised service manual pages. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 2-67 Alignment Specifications For Sales Code ACR POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Alignment Specifications For Sales Code ACR Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions > Page 1477 2-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 1483 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 020694 > Jul > 94 > Alignment Specification - Revisions Alignment: All Technical Service Bulletins Alignment Specification - Revisions NO: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 SUBJECT: Service Manual Revision - Alignment Specifications MODELS: 1995 (PL) Neon DISCUSSION: This technical service bulletin references revised service manual pages. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 2-67 Alignment Specifications For Sales Code ACR POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Alignment Specifications For Sales Code ACR Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions > Page 1492 2-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1493 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1494 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1495 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1496 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1497 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1498 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications Alignment: Specifications Front Alignment Specifications The content of this article reflects the changes called out by TSB 02-06-94. CAMBER [01] Limits Neon .................................................................................................................................................... ................................................... -0.4° to +0.4° ACR ........................................................................... ............................................................................................................................. -2.4° to +0.4° Desired ................................................................................................................................................ ........................................................................... 0° CASTER [01] Limits ................................................................................................................................................... ....................................................... +1.8° to +3.8° Desired ................................................................. ....................................................................................................................................................... 2.8° CROSS-CASTER [02] Limits ................................................................................................................................................... ............................................................ 1.0° or less Desired ................................................................ ........................................................................................................................................................ 0.0° TOTAL TOE Limits Neon .................................................................................................................................................... ................................................... -0.1° to +0.3° ACR ........................................................................... ............................................................................................................................. -0.7° to +0.3° Desired ................................................................................................................................................ ........................................................................ 0.1° [01] -- Reference angle only. Not adjustable. [02] -- Side to side caster differential not to exceed 1.0° or less. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications > Page 1501 Alignment: Specifications Rear Alignment Specifications The content of this article reflects the changes called out by TSB 02-06-94. CAMBER [01] Limits Neon .................................................................................................................................................... ............................................... -0.75° to +0.25° ACR ........................................................................... ........................................................................................................................... -1.0° to +0.25° Desired ................................................................................................................................................ ..................................................................... -0.25° TOTAL TOE [01] Limits Neon .................................................................................................................................................... ................................................... -0.1° to +0.3° ACR ........................................................................... ............................................................................................................................. -0.5° to +0.3° Desired ................................................................................................................................................ ...................................................................... +0.1° THRUST ANGLE [01] .......................................................................................................................... .......................................................... -0.1° to +0.1° [01] -- Reference angle only. Non-adjustable. NOTE: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is Toe-in, negative is Toe-out. Total toe must be equally splt between each front wheel to ensure a centered steering wheel. Left and Right toe must be equal to within 0.02°. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. NOTE: No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Center steering wheel and lock in place using steering wheel clamp. 3. Jounce vehicle, then read front alignment settings and compare to specifications. 4. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 5. Raise and support vehicle, then remove original upper bolt attaching front strut clevis bracket to steering knuckle. 6. Loosen lower bolt attaching strut clevis bracket to steering knuckle only enough to allow knuckle to move in clevis bracket. 7. Install bolt from service kit into upper strut clevis bracket to steering knuckle mounting hole. 8. Install nut provided by service kit on replacement bolt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1504 9. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 10. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 11. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 12. Adjust camber to preferred setting by pushing or pulling top of tire. 13. Tighten upper and lower strut clevis bracket bolts. 14. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque both front strut clevis brackets to 40 ft. lbs. plus an additional 1/4 turn. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams, until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1505 Preliminary Inspection - Ensure vehicle has a full tank of gas when wheel alignment specifications are checked or adjusted. One full tank of gas is approximately 75 lbs. - If tank is not full, this change in weight will affect curb height of vehicle and alignment specifications. - Check and adjust tire pressure. Ensure all tires are the same size. - Inspect all suspension components for looseness or damage. Components showing signs of wear or damage should be replaced before alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1506 Alignment: Service and Repair Rear Alignment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. - No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Jounce vehicle and read rear alignment settings and compare to specifications. 3. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 4. Raise and support vehicle, then remove original upper bolt attaching rear strut clevis bracket to rear knuckle. 5. Loosen lower bolt attaching strut clevis bracket to rear knuckle only enough to allow knuckle to move in clevis bracket. 6. Install bolt from service kit into upper strut clevis bracket to rear knuckle mounting hole. 7. Install nut provided by service kit on replacement bolt. 8. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 9. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 10. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 11. Adjust camber to preferred setting by pushing or pulling top of tire. 12. Tighten upper and lower strut clevis bracket bolts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1507 13. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque rear strut clevis brackets to 70 ft.-lbs. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 1 Air Cleaner AIR CLEANER Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. The air cleaner attaches to a bracket on the rear of the cylinder head (Fig. 1). An ambient air duct supplies underhood air for the engine. FILTER ELEMENT REPLACEMENT 1. Unfasten clasps of front of air cleaner lid. Lift lid off of air cleaner housing. 2. Remove clean air duct from throttle body. 3. Remove make-up air hose. Fig. 2 Air Cleaner Housing And Element 4. Remove filter element (Fig. 2). 5. If necessary, clean the inside of the air cleaner housing. 6. Install new filter element. 7. Place lid over air cleaner housing. Snap clasps over the air cleaner lid. 8. Install clean air duct to throttle body CAUTION: DO NOT Over Torque Air Cleaner Housing Cover Clamps. 9. Tighten air cleaner cover clamps to (15-25 in lb). 10. Install make-up air hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1524 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1535 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1538 Ignition Cable: Component Tests and General Diagnostics Testing Fig. 4 Setting Spark Plug Electrode Gap TESTING USING AN OSCILLOSCOPE When testing cables for punctures and cracks with an oscilloscope, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during test or possible heat damage to catalytic converter will occur. Total test time must not exceed one minute. NOTE: Test must be performed at idle only. IF AN OSCILLOSCOPE IS NOT AVAILABLE, TEST CABLES AS FOLLOWS: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Cracked, leaking or faulty cables should be replaced. 3. Use an ohmmeter to check cables for opens, loose terminals or high resistance. a. Remove cable from spark plug. b. Remove cable from the coil tower. c. Connect the ohmmeter between spark plug end terminal and the coil end terminal. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in same manner. CABLE RESISTANCE CHART MINIMUM MAXIMUM 250 Ohms/Inch 1,000 Ohms/Inch 3,000 Ohms/Foot 12,000 Ohms/Foot Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1539 Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 1542 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. On SOHC engines, be sure that dual plastic clip holds #1, #2 cables off of valve cover and that PCV hose plastic clip holds #3 cable away from metal PCV clamp and edge of air duct. On DOHC, be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 1547 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1550 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1551 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1552 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1553 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1556 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1557 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1558 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1559 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1560 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1561 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1562 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1563 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1564 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1565 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair Timing Belt: Service and Repair TIMING BELT SERVICE VALVE TIMING CHECK-TIMING BELT COVER INSTALLED 1. Remove number one spark plug. 2. Using a dial indicator; set number one cylinder to TDC on the compression stroke. 3. Remove the access plug from the outer timing belt cover. 4. Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover. REMOVAL 1. Remove accessory drive belts. Refer to Cooling System for procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1575 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827. 4. Lower vehicle and place a jack under engine. 5. Remove right engine mount. 6. Remove right engine mount bracket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1576 7. Remove front half of timing belt cover. Caution: Align camshaft and crankshaft timing marks before removing the timing belt. 8. Loosen timing belt tensioner screws and remove timing belt and tensioner. SERVICING CAMSHAFT OIL SEALS/REPLACEMENT CAUTION: Do not rotate the camshaft of crankshaft when timing belt is removed, damage to the engine may occur. 1. With timing belt removed, remove camshaft sprocket bolt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1577 2. Modify Special Tool C-4687-1 as shown in image above. Hold camshaft sprocket with modified tool while removing/installing bolt. Remove sprocket from camshaft. 3. Remove camshaft seal using Special C-4679 . CAUTION: Do not nick shaft seal surface of bore. 4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. 5. Install camshaft seal flush with cylinder head using Special Tool MD 998306. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1578 6. Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tool C-4687-1 (shown in image above) and tighten bolt to 115 Nm (85 ft. lbs.). CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE TIMING BELT TENSIONER / TIMING BELT INSTALLATION 1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. 2. Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine. 3. When plunger is compressed into the tensioner body install a 1.9 mm (5/64) allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1579 4. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC. 5. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover. 6. Move crankshaft to 1/2 mark before TDC for belt installation. 7. Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket. 8. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1580 9. Using a torque wrench on the tensioner pulley apply 28 Nm (250 in. lbs.) of torque. 10. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 in. lbs.). 11. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 13. Install front half of timing cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 1581 14. Install engine mount bracket. 15. Install Right engine mount. 16. Remove jack from under engine. 17. Install crankshaft damper using M12-1.75 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt an tighten to 142 Nm (105 ft. lbs.). 18. Install accessory drive belts. Refer to Cooling System and Accessory Drive for procedure. 19. Raise vehicle on hoist and install right inner splash shield. 20. Perform relearn camshaft and crankshaft alignment procedure in Engine Miscellaneous of the DRB Scan Tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1590 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1596 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1597 Drive Belt: Adjustments Fig. 42 Serpentine Drive Belt Routing 1. Loosen T-Bolt locking nut and pivot bolt to replace Poly V-belt and/or adjust belt tension. 2. Tighten adjusting bolt to adjust belt tension to specification shown in belt tension chart. 3. Tighten T-Bolt locking nut and pivot bolt to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 1 Air Cleaner AIR CLEANER Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. The air cleaner attaches to a bracket on the rear of the cylinder head (Fig. 1). An ambient air duct supplies underhood air for the engine. FILTER ELEMENT REPLACEMENT 1. Unfasten clasps of front of air cleaner lid. Lift lid off of air cleaner housing. 2. Remove clean air duct from throttle body. 3. Remove make-up air hose. Fig. 2 Air Cleaner Housing And Element 4. Remove filter element (Fig. 2). 5. If necessary, clean the inside of the air cleaner housing. 6. Install new filter element. 7. Place lid over air cleaner housing. Snap clasps over the air cleaner lid. 8. Install clean air duct to throttle body CAUTION: DO NOT Over Torque Air Cleaner Housing Cover Clamps. 9. Tighten air cleaner cover clamps to (15-25 in lb). 10. Install make-up air hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1607 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Oil Filter Application Change Oil Filter: Technical Service Bulletins Engine - Oil Filter Application Change NO: 09-03-96 GROUP: Engine DATE: Mar. 1, 1996 SUBJECT: 2.0L/2.4L Engine Oil Filter Application THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-95 DATED APR. 7, 1995 AND 09-15-95 DATED JUN. 30, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS INCLUDE ADDITIONAL MODELS AND ADDITIONAL INFORMATION IN THE DISCUSSION. MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager 1996 (GS) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L OR 2.4L ENGINE EXCEPT (FJ) AVENGER/SEBRING COUPE/TALON. DISCUSSION: Vehicles equipped with a 2.0L or 2.4L engine now have oil filter P/N 4105409 installed when shipped from the assembly plant. This oil filter is smaller in diameter and shorter than oil filter, P/N 5281090, commonly found on most Chrysler products. The smaller oil filter, P/N 4105409, is specified for the applications listed above to provide additional ground clearance. It should be used whenever a filter is changed, regardless of what filter was on the vehicle before service. Failure to use the correct oil filter may result in oil filter damage. The smaller oil filter, P/N 4105409, must be changed every time the oil is changed on all 2.4L engine equipped vehicles and 2.0L equipped JA and GS vehicles. Filter maintenance intervals have not changed for any other vehicles. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1612 Oil Filter: Service and Repair FILTER CAUTION: When servicing the oil filter avoid deforming the filter can by installing the removal install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1620 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps Power Steering Line/Hose: Customer Interest Power Steering System - Rattle Noise on Bumps NO: 19-06-94 GROUP: Steering DATE: Aug. 5, 1994 SUBJECT: Power Steering System Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 7/11/94, MDH (07-11-XX), EQUIPPED WITH POWER STEERING. SYMPTOM/CONDITION: A metallic rattle that appears to be coming from the front suspension or through the steering column. This noise usually occurs when the vehicle is driven through a turn and the tire goes over a pot hole, tar strip, or other surface irregularity. PARTS REQUIRED: 1 4626896 Power Steering Fluid Return Line 1 4361097 O-Ring, Banjo Bolt to Hose 1 4626691 O-Ring, Hose to Pump AR 4318085 Power Steering Fluid (16 Oz) AR 4549617 Power Steering Fluid (1 Qt) REPAIR PROCEDURE: This bulletin involves replacing the power steering fluid return line with a revised part and tightening the power steering pump housing bolts to a revised torque specification. 1. Remove the power steering fluid return line and install the revised power steering fluid return line, P/N 4626896, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-13 to 19-15. 2. Before adding power steering fluid to the proper level, proceed to Step 3. 3. Remove the power steering pump as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 19-16. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps > Page 1629 4. Tighten the four power steering pump housing bolts to 243 In.Lbs. (27 N-m). See Illustration. NOTE: IF THESE BOLTS ARE NOT TIGHTENED TO THE REVISED TORQUE SPECIFIED, PUMP NOISE ON COLD STARTS MAY BECOME UNACCEPTABLE. 5. Install the power steering pump in the vehicle and refill the system with fluid as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-17 to 19-18. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps Power Steering Line/Hose: All Technical Service Bulletins Power Steering System - Rattle Noise on Bumps NO: 19-06-94 GROUP: Steering DATE: Aug. 5, 1994 SUBJECT: Power Steering System Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 7/11/94, MDH (07-11-XX), EQUIPPED WITH POWER STEERING. SYMPTOM/CONDITION: A metallic rattle that appears to be coming from the front suspension or through the steering column. This noise usually occurs when the vehicle is driven through a turn and the tire goes over a pot hole, tar strip, or other surface irregularity. PARTS REQUIRED: 1 4626896 Power Steering Fluid Return Line 1 4361097 O-Ring, Banjo Bolt to Hose 1 4626691 O-Ring, Hose to Pump AR 4318085 Power Steering Fluid (16 Oz) AR 4549617 Power Steering Fluid (1 Qt) REPAIR PROCEDURE: This bulletin involves replacing the power steering fluid return line with a revised part and tightening the power steering pump housing bolts to a revised torque specification. 1. Remove the power steering fluid return line and install the revised power steering fluid return line, P/N 4626896, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-13 to 19-15. 2. Before adding power steering fluid to the proper level, proceed to Step 3. 3. Remove the power steering pump as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 19-16. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps > Page 1635 4. Tighten the four power steering pump housing bolts to 243 In.Lbs. (27 N-m). See Illustration. NOTE: IF THESE BOLTS ARE NOT TIGHTENED TO THE REVISED TORQUE SPECIFIED, PUMP NOISE ON COLD STARTS MAY BECOME UNACCEPTABLE. 5. Install the power steering pump in the vehicle and refill the system with fluid as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-17 to 19-18. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1641 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 1642 Coolant: Specifications Coolant Capacity [04] .......................................................................................................................... ....................................................................... 7.4 qts Radiator Cap Relief Pressure .............................................................................................................. ......................................................................... 16 psi Thermo. Opening Temp. ..................................................................................................................... ........................................................................ 195 °F Fuel Tank ............................................................................................................................................. ....................................................................... 11 gals Engine Oil Refill [03] ............................................................................................................................ ...................................................................... 4.5 qts Auto. Transaxle Oil [02] ....................................................................................................................... ........................................................................... [01] Man. Transaxle Oil .............................................................................................................................. ............................................................... 4.0 - 4.6 pts [01] Oil change only ............................................................................................................................. ................................................................... 4.0 qts. After overhaul: except fleet models ............................................................................................................................................................. 8.9 qts. fleet models ............................................................................................................................ ............................................ 9.2 qts. [02] Approximate capacity. Make final inspection with dipstick. [03] Includes oil filter. [04] Includes heater and coolant recovery system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1647 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1648 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1649 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1650 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1651 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transaxle/Transmission - Automatic CAPACITY Estimated service refill ......................................................................................................................... .................................................. 3.8 l (4.0 qts) Overhaul refill with torque converter ...................................................................................................................................................... 8.2 l (8.8 qts) TYPE ................................................................................................................................................... ................................................. MOPAR ATF+4 [1] [1] Or Dexron II. Initial Refill Capacity CAPACITY Estimated service refill ......................................................................................................................... .................................................. 3.8 l (4.0 qts) Overhaul refill with torque converter ...................................................................................................................................................... 8.2 l (8.8 qts) TYPE ................................................................................................................................................... ................................................. MOPAR ATF+4 [1] [1] Or Dexron II. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1654 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Whenever the factory fill fluid is changed, only fluids of the type labeled MOPAR ATF+4 (Type 9602) should be used. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications CAPACITY ........................................................................................................................................... ............................................................ 2.1 l (2.2 qt) TYPE .................................................................. ........................................................................................................................... MOPAR Type M.S.9417 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications Oil Pressure Specifications Curb Idle: 25 kPa (4 psi) minimum 3000 RPM: 170-550 kPa (25-80 psi) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1662 Engine Oil: Capacity Specifications TYPE ................................................................................................................................................... ...................................................... SG or SG/CD [1] VISCOSITY Below 38° C (100° F) ........................................................................................................................... ............................................................ 5W-30 Above 38° C (100° F) .................................................. ................................................................................................................................... 10W-30 CAPACITY With filter .............................................................................................................................................. ............................................... 4.25 l (4.5 qts) Without filter ................................................................. ......................................................................................................................... 3.8 l (4.0 qts) [1] Energy Conserving II Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1671 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1677 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1678 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1679 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1684 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1690 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1691 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1692 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection NO.: 24-13-94 GROUP: Air Conditioning DATE: Sep. 9, 1994 SUBJECT: R-134a Refrigerant Leak Detection MODELS: 1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1994 - 1995 (AB) Ram Van/Ram Wagon 1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1994 - 1995 (AN) Dakota/Dakota Cab & Chassis 1994 (AP) Shadow/Sundance 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1994 (BD) Laser/Talon (Midyear Change) 1994 - 1995 (BR) Ram Truck 1994 - 1995 (B7) Stealth 1994 - 1995 (B8) Colt Vista/Summit Wagon 1994 - 1995 (B9) Colt/Summit 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon 1993 - 1995 (SR) Viper 1994 - 1995 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular structure. Listed below are the R-134a leak detection units currently approved by Chrysler and SAE: HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA Leybold Inficon Models HLD4000 and D/TEC OTC/Yokogawa Model H10N NOTE: LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL, EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM, DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL PROVIDE ACCURATE LEAK DETECTION. TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS SAE Recommended Practice J1628 1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's operating instructions. 2. Leak test with the engine not in operation. 3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may not be measurable since this pressure may not be reached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection > Page 1697 4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No cleaners or solvents shall be used, since many electronic detectors are sensitive to their ingredients. 5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area should be carefully checked with the detector probe, as well as all fittings, hose to line couplings, refrigerant controls, service ports with caps off, brazed or welded areas, and areas around attachment points and holddowns on lines and components. 6. Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. If a leak is found, always continue to test the remainder of the system. 7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50 mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around the position. Slower and closer movement of the probe greatly improves the likelihood of finding a leak. 8. An apparent leak should be verified at least once by blowing shop air into the area of the suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks, blowing out the area with shop air often helps locate the exact position of a leak. 9. Leak testing of the evaporator core while in the air conditioning module should be accomplished by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off, then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting the leak detector probe into the condensate drain hole if no water is present, or into the closest opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent duct. If the detector alarms, a leak apparently has been found. NOTE: R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C MODULE. 9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions included with the detector, or a minimum of 2 minutes. 10. Following any service to the refrigerant system of the vehicle, and any other service which disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant system should be done. NOTE: CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Page 1698 Refrigerant: Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Capacity 1.75 lb (US) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Fluid Specifications Fluid Specifications Ounces Viscosity 4.75 oz (US) ND8 PAG Polyalkaline Glycol Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1702 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1708 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1714 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Fuse: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Fuse: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 Fuse: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Fuse Block: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Fuse Block: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Fuse Block: Mechanical Diagrams Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CHECK ENGINE (MALFUNCTION INDICATOR LAMP) The Check Engine lamp (Malfunction Indicator lamp) illuminates when the ignition switch is in the ON position, and prior to starting the vehicle. The lamp turns off after the vehicle is started. If, while the vehicle is running, a problem is detected in the engine control system, the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Tires: Customer Interest Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1784 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1785 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1786 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1787 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Tires: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1797 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1798 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1799 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1800 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Wheels: Customer Interest Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1814 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1815 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1816 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1817 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Wheels: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1827 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1828 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1829 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 1830 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: Customer Interest Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 1844 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: All Technical Service Bulletins Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 1850 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1853 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1854 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise Wheel Cover: Customer Interest Wheel Cover - Clicking Noise NO: 22-05-94 GROUP: Wheels & Tires DATE: Sep. 30, 1994 SUBJECT: Wheel Cover Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO SPORT MODELS EQUIPPED WITH 14", CENTRIFUGE WHEEL COVERS BUILT PRIOR TO 5/9/94, (MDH 05-09-XX). SYMPTOM/CONDITION: A "cycling" clicking noise coming from the wheel area of the vehicle. The sound is most noticeable when the vehicle is driven at low speeds. DIAGNOSIS: Remove all four wheel covers and drive the vehicle. If the noise is eliminated, proceed with the repair procedure. PARTS REQUIRED: AR 4472591 Cover, Full Wheel, Brushed Aluminum AR 4472593 Cover, Full Wheel, White REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise > Page 1863 This bulletin involves replacing all four wheel covers with revised parts. See illustration for identification of wheel covers. Replace the wheel covers with appropriate parts, as called out in the parts required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise Wheel Cover: All Technical Service Bulletins Wheel Cover - Clicking Noise NO: 22-05-94 GROUP: Wheels & Tires DATE: Sep. 30, 1994 SUBJECT: Wheel Cover Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO SPORT MODELS EQUIPPED WITH 14", CENTRIFUGE WHEEL COVERS BUILT PRIOR TO 5/9/94, (MDH 05-09-XX). SYMPTOM/CONDITION: A "cycling" clicking noise coming from the wheel area of the vehicle. The sound is most noticeable when the vehicle is driven at low speeds. DIAGNOSIS: Remove all four wheel covers and drive the vehicle. If the noise is eliminated, proceed with the repair procedure. PARTS REQUIRED: AR 4472591 Cover, Full Wheel, Brushed Aluminum AR 4472593 Cover, Full Wheel, White REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise > Page 1869 This bulletin involves replacing all four wheel covers with revised parts. See illustration for identification of wheel covers. Replace the wheel covers with appropriate parts, as called out in the parts required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1879 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1885 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 1886 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 203 Nm (150 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque Lug Nuts 135 Nm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners to 12 Nm (105 in. lbs.) in sequence shown here. 2. Apply Mopar Gasket Marker to No. 1 and No. 6 bearing caps. Install bearing caps and tighten M8 fasteners to 24 Nm (215 in. lbs.) 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Bearing Clerance 0.053-0.093 in Lift Intake 0.307 in Lift Exhaust 0.277 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1905 Camshaft: Description and Operation CAMSHAFT: The nodular iron camshaft has five bearing journals and 3 cam lobes per cylinder. Provision for cam position sensor on the cam at the rear of cylinder head which also acts as thrust plate. A hydrodynamic oil seal is used for oil control at the front of the camshaft. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1906 Camshaft: Service and Repair CAMSHAFT SERVICE Refer to TIMING SYSTEM AND SEALS for camshaft timing belt and sprocket removal and installation, and CYLINDER HEAD. REMOVAL 1. Remove the cylinder head cover. 2. Mark rocker arm shaft assemblies for installation. 3. Remove rocker arm shaft bolts. Refer to procedure outlined in this section. 4. Remove the timing belt and camshaft sprocket. Refer to timing belt service outlined in this section. 5. Remove camshaft sensor and remove camshaft from the rear of the head. INSPECTION Check oil feed holes for blockage. Inspect cylinder head journals for wear, Refer to CYLINDER HEAD, Inspect and Specifications. Check camshaft bearing journals for scratches and worn areas. If light scratches are present, they may be removed with 400 grit sand paper. If deep scratches are present, replace the camshaft and check the cylinder head for damage. Replace the cylinder head if worn or damaged. Check the lobes for pitting and wear. If the lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace rocker arm/hydraulic lash adjuster if worn or damaged. If lobers show signs of pitting on the nose, flank or base circle; replace the camshaft. CAMSHAFT END PLAY 1. Oil camshaft journals and install camshaft without rocker arm assemblies. Install cam sensor and tighten screws to specified torque. 2. Using a suitable tool, move camshaft as far rearward as it will go. 3. Zero dial indicator. 4. Move camshaft as far forward as it will go. 5. End play travel: 0.13-0.33 mm (0.005 - 0.013 inch.). INSTALLATION 1. Lubricate camshaft journals. Install camshaft into the cylinder head carefully. 2. Install cam sensor and tighten fasteners to 9.5 Nm (85 in. lbs.). 3. Install camshaft seal. Camshaft must be installed before the camshaft seal is installed. 4. Install camshaft sprocket and tighten to 115 Nm (85 ft. lbs.). 5. Install timing belt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1907 6. Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence to 23 Nm (200 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Diameter .............................................................................................................................................. ................. 19.996 - 19.984mm (0.786 - 0.7867 inch) RETAINERS (WIDTH): Intake (All) ........................................................................................................................................... ........................................... 28.46 mm (1.12 inch) Exhaust: 1 & 5 .................................................................................................................................................... ....................................... 29.20 mm (1.14inch) 2, 3,and 4 ................................................................... ................................................................................................................ 40.45 mm (1.59 inch) Mounting Bolts ..................................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement Rocker Arm Assembly: Service and Repair Rocker Arm Replacement 1. Disconnect battery ground cable. 2. Remove valve cover as outlined under "Valve Cover, Replace". 3. Identify rocker are shaft assemblies, then remove attaching bolts and rocker arm shaft assemblies. 4. Reverse procedure to install, noting the following: a. Install rocker arm and shaft assemblies with notches on shafts facing up and toward timing belt side of engine. Fig. 17 Rocker Arm Shaft Notch Alignment. Fig. 18 Rocker Arm Shaft Tightening Sequence. b. Tighten bolts to specifications in sequence shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1913 Rocker Arm Assembly: Service and Repair Rocker Arm/Hydraulic Lash Adjuster ROCKER ARM/HYDRAULIC LASH ADJUSTER REMOVAL 1. Remove valve cover. 2. Remove rocker arm assembly. 3. Mark rocker arm/hydraulic lash adjuster assemblies for reassembly in there original position. Remove rocker arm/hydraulic lash adjuster assembly. Lash adjusters are serviced as a assembly with the rocker arm. 4. Inspect the rocker arm/hydraulic lash adjuster assembly for wear or damage. Replace assembly as necessary. INSTALLATION 1. Install rocker arm/hydraulic lash adjuster assembly making sure that adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed. If there is excessive plunger travel. Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. 2. Install rocker arm assembly. 3. Install valve cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Main and rod bearings are available in the standard size and in undersizes of 0.025 mm and 0.250 mm. Torque main bearing M8 cap bolts to 25 ft-lbs and M11 bolts to 60 ft-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1918 Connecting Rod Bearing: Service and Repair CONNECTING ROD BEARING Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch.) off center and away from the oil hole. In addition, suspect areas can be checked by placing plastigage in the suspect area. 4. Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the connecting rod being checked starts moving toward the top of the engine. Only then should the cap be assembled and torqued to specifications. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. 5. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. 6. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 inch) is usually the most appropriate for checking engine bearing proper specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Nut 20 ft.lb NOTE: Plus an additional 1/4 turn. Large End Bore Diameter 2.0075-2.0081 in Total Weight 1.20 lb (US) Bearing Oil Clearance 0.001-.0023 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair See Camshaft and Crankshaft timing proceduress. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main and rod bearings are available in the standard size and in undersizes of 0.025 mm and 0.250 mm. Torque main bearing M8 cap bolts to 25 ft-lbs and M11 bolts to 60 ft-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1928 Crankshaft Main Bearing: Description and Operation CRANKSHAFT MAIN BEARINGS The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bed- plate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal. CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to .025 mm (.001 inch). Journal grinding should not exceed .305 mm (.012 inch) under the standard journal diameter. Do NOT grind thrust faces of Number 3 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes arid clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.016 mm (.0006 inch), .032 mm (.0012 inch), .250 mm (.010 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1929 1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Refer to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing: Service and Repair Removal and Installation See Crankshaft for Main Bearing removal. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1932 Crankshaft Main Bearing: Service and Repair Inspection MAIN BEARINGS Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This may be accomplished with the engine on an engine stand. Rotate the engine upside down, so the crankshaft weight is being supported by the engine block. 3. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 inch) is usually the most appropriate for checking engine bearing proper specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications M11 Main Cap Bolts 81 Nm M8 Bedplate Bolts 34 Nm Out-Of-Round 0.0001 in End Play 0.0035-0.0094 in Rod Journal Diameter 1.8894-1.8900 in Main Bearing Clearance 0.0008-0.0024 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1936 Crankshaft: Description and Operation CRANKSHAFT: A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 52 mm diameter main and 48 mm diameter crank pin journals (all) have undercut fillet radiuses that are deep rolled for added strength. To optimize bearing loading 8 counterweights are used. Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing. A sintered iron timing belt sprocket is mounted on the crankshaft nose. This sprocket provides motive power; via timing belt to the camshaft sprocket providing timed valve actuation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1937 Crankshaft: Service and Repair CRANKSHAFT REMOVAL 1. Remove oil filter and adapter from bedplate. 2. Remove crankcase baffle from engine. Remove all main bearing cap bedplate bolts from the engine block. 3. Using a mallet tap the bedplate loose from the engine block dowel pins. CAUTION: Do not pry up on one side of the bed- plate. Damage may occur to cylinder block and bed- plate alignment. 4. Bedplate should be removed evenly from the cylinder block dowel pins. 5. Lift out crankshaft from cylinder block. Be sure not damage the main bearings or journals when removing the crankshaft. OPTIONAL CRANKSHAFT END PLAY CHECK 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek, using care not to damage any bearing surface. Do not loosen main bearing cap. 2. Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play. CRANKSHAFT INSTALLATION 1. Install the main bearing shells with the lubrication groove in the cylinder block. Install 0-ring into recess in the block. 2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. CAUTION: Do Not get oil on the bedplate mating surface. It will may effect the sealer ability to seal the bedplate to cylinder block. 3. Oil the bearings and journals and install crankshaft. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1938 CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. 4. Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of anaerobic sealer P/N 4773257 to cylinder block. 5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block. 6. Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil. 7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. Then torque these bolts to 34 Nm (25 ft. lbs.). 8. Install main bearing bedplate to engine block bolts (1 thru 10) and torque each bolt to 81 Nm (60 ft. lbs.) in sequence. 9. Install main bearing bedplate to engine block bolts (11 thru 20), with baffle studs in positions 12,13 and 16 and torque each bolt to 34 Nm (25 ft. lbs.) in sequence shown. 10. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1939 11. Install crankcase baffle into the opening in the block. Attach baffle to main bearing cap stud. Tighten nuts to 34 Nm (25 ft. lbs.). 12. Install oil filter adapter and filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper Torque Crankshaft Damper Torque Damper Bolt 142 Nm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1943 Harmonic Balancer - Crankshaft Pulley: Service and Repair NOTE: If a gap is found in the crankshaft damper, in the area where the Poly-V Generator belt rides this is normal and is acceptable. REMOVAL 1. Remove accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A. or equivalents. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1944 INSTALLATION 1. Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792, or equivalent. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). 2. Install accessory drive belts. 3. Raise vehicle on hoist and install right inner splash shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Mechanical Dimensions Piston: Specifications Clearance botton of skirt 0.0002-0.0015 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Mechanical Dimensions > Page 1949 Piston: Specifications Piston and Rod Assembly The L or H stamping on the front portion of the piston must face toward the front of the engine. The connecting rod and cap are stamped on the side with a cylinder number identification. The numbered side of the connecting rod cap must be installed on the same side as the numbered side of the rod. When installing cap bolts, torque to 20 ft-lbs, then tighten an additional 1/4 turn. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1950 Piston: Description and Operation PISTONS: There is no provision for free wheeling valve train. Piston has a unique height. All engines use pressed-in piston pins to attach forged powdered metal connecting rods. The connecting rods are a cracked cap design and are not repairable. Hex head cap screw are used to provide alignment and durability in the assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1951 Piston: Service and Repair PISTON AND CONNECTING ROD ASSEMBLY REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number. 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons have stamping in the front half of the piston facing towards the front of engine. The stamping is a weight identification for the assembly L is for light and H is for heavy. These assemblies should all be the same weight class. Service piston assemblies are marked with a S and can be used with either L or H production assemblies. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. 7. Piston and Rods are serviced as an assembly. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1952 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The weight stamp designation L for light or H for heavy assembly will be in the front half of the piston facing toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. Install rod caps. Install cleaned and oiled rod bolts and tighten to 27 Nm (20 ft. lb.) Plus 1/4 turn. CONNECTING RODS 1. See main bearing for measureing and specifiction procedures. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. The rod bearing bolts should not be reused. 2. Before installing the NEW bolts the threads should be oiled with clean engine oil. 3. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1953 4. Tighten the bolts to 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Do not use a torque wrench for last step. 5. Using a feeler gauge, check connecting rod side clearance. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pins Piston Pins Clearance In Piston 0.0002-0.0007 in In Rod Interference 0.0007-0.0017 in Diameter 0.8267-0.8269 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Top Ring Gap 0.009-0.020 in 2nd Ring Gap 0.019-0.031 in Ring Width 0.046-0.047 in Ring Clearance 0.0010-0.0026 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1960 Piston Ring: Description and Operation PISTON RINGS: The piston rings include a molybdenum faced top ring for reliable compression sealing and a taper faced intermediate ring for additional cylinder pressure control. Oil Control Ring Package contains of 2 steel rails and an expander spacer. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1961 Piston Ring: Service and Repair SIZING PISTONS Piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin about 17.5 mm (11/16 inch) from the bottom of the skirt. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Refer to specifications. Correct piston to bore clearance must be established in order to assure quiet and economical operation. Pistons and cylinder bores should be measured at normal room temperature, 70°F. (21°C). PISTON RINGS REMOVAL 1. ID mark on face of upper and intermediate piston rings must point toward piston crown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1962 2. Using a suitable ring expander, remove upper and intermediate piston rings. 3. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 4. Clean ring grooves of any carbon deposits. FITTING RINGS 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. 2. Check piston ring to groove side clearance. PISTON RINGS-INSTALLATION 1. Install rings with manufacturers I.D. mark facing up, to the top of the piston. CAUTION: Install piston rings in the following order: a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1963 d. No.2 Intermediate piston ring. e. No.1 Upper piston ring. 2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. 3. Install upper side rail first and then the lower side rail. 4. Install No.2 piston ring and then No.1 piston ring. 5. Position piston ring end gaps. 6. Position oil ring expander gap at least 450 from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1971 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Diameter .............................................................................................................................................. ................. 19.996 - 19.984mm (0.786 - 0.7867 inch) RETAINERS (WIDTH): Intake (All) ........................................................................................................................................... ........................................... 28.46 mm (1.12 inch) Exhaust: 1 & 5 .................................................................................................................................................... ....................................... 29.20 mm (1.14inch) 2, 3,and 4 ................................................................... ................................................................................................................ 40.45 mm (1.59 inch) Mounting Bolts ..................................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement Rocker Arm Assembly: Service and Repair Rocker Arm Replacement 1. Disconnect battery ground cable. 2. Remove valve cover as outlined under "Valve Cover, Replace". 3. Identify rocker are shaft assemblies, then remove attaching bolts and rocker arm shaft assemblies. 4. Reverse procedure to install, noting the following: a. Install rocker arm and shaft assemblies with notches on shafts facing up and toward timing belt side of engine. Fig. 17 Rocker Arm Shaft Notch Alignment. Fig. 18 Rocker Arm Shaft Tightening Sequence. b. Tighten bolts to specifications in sequence shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1977 Rocker Arm Assembly: Service and Repair Rocker Arm/Hydraulic Lash Adjuster ROCKER ARM/HYDRAULIC LASH ADJUSTER REMOVAL 1. Remove valve cover. 2. Remove rocker arm assembly. 3. Mark rocker arm/hydraulic lash adjuster assemblies for reassembly in there original position. Remove rocker arm/hydraulic lash adjuster assembly. Lash adjusters are serviced as a assembly with the rocker arm. 4. Inspect the rocker arm/hydraulic lash adjuster assembly for wear or damage. Replace assembly as necessary. INSTALLATION 1. Install rocker arm/hydraulic lash adjuster assembly making sure that adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed. If there is excessive plunger travel. Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. 2. Install rocker arm assembly. 3. Install valve cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1981 Valve Cover: Service and Repair CYLINDER HEAD COVER REMOVAL 1. Disconnect battery ground cable, then remove air cleaner inlet duct. 2. Remove coil pack, then remove valve cover bolts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1982 3. Remove cover from engine. 4. Reverse procedure to install, noting the following: a. Install a new valve cover gasket. b. Tighten valve cover bolts to 12 Nm (105 in. lbs.). Caution: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. COVER INSTALLATION 1. Install new valve cover gasket Caution: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. 2. Install cover assembly to head and tighten fasteners to 12 Nm (105 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1983 3. Install ignition coil pack. Tighten fasteners to 23 Nm (200 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle 0.050 deg Run Out (Max) 0.002 in Valve Seat Width 0.9-1.3 mm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1987 Valve Seat: Service and Repair REFACING VALVES AND VALVE SEATS 1. The intake and exhaust valve seats and valve face have a 45 degree angle. 2. Inspect the remaining margin after the valves are refaced. Intake valves with less than 95 mm (1/32 inch.) margin and Exhaust valves with less than 1.05 mm (3/64 inch) margin should be discarded. 3. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 4. Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator. Total runout should not exceed 0.051 mm (0.002 inch.) (total indicator reading). 5. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face, raise valve seat with a 65 degrees stone. - Intake valve seat diameter is 33 mm (1.299 inch.) - Exhaust valve seat diameter is 28 mm (1.102 inch.) Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. 6. When seat is properly positioned the width of intake and exhaust seats should be 0.9 to 1.3 mm (0.35 to 0.051 inch.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1988 7. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to 47.99 mm (1.889 in.) for exhaust valve and 48.04 mm (1.891 in.) for intake valve over spring seat when installed in the head. The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Removal and Installation Valve Spring: Service and Repair Removal and Installation See Valve Intake/Exhaust. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Removal and Installation > Page 1993 Valve Spring: Service and Repair Inspection VALVE INSPECTION 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Measure stem about 90 mm beneath the valve lock grooves. 3. If valve stems are worn more than 0.05 mm (.002 inch.), replace valve. VALVE GUIDES 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom. Replace guides if they are not within specification. 3. Check valve guide height. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Removal and Installation > Page 1994 TESTING VALVE SPRINGS 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example, the compression length of the spring to be tested is 33.34 mm (1-5/16 inches). Turn tool table until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Discard the springs that do not meet specifications. The Following specifications apply to both intake and exhaust valve springs; - Valve Closed Nominal Tension- 75 ft. lbs. @ 39.2 mm (1.54 in.) - Valve Open Nominal Tension- 176 ft. lbs. @ 31.4 mm (1.24 in.) 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1998 Valve: Description and Operation VALVES: 4-valves per cylinder are actuated by roller rocker arms/hydraulic lash adjusters assemblies which pivot on rocker arm shafts. All valves have 6 mmdiameter chrome plated valve stems. The valve train has 33 mm (1.299 inch)diameter intake valves and 28 mm (1.10 inch) diameter exhaust valves. Viton rubber valve stem seals are integral with spring seats. Valve springs, spring retainers, and locks are conventional. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1999 Valve: Service and Repair REFACING VALVES AND VALVE SEATS 1. The intake and exhaust valve seats and valve face have a 45 degree angle. 2. Inspect the remaining margin after the valves are refaced. Intake valves with less than 95 mm (1/32 inch.) margin and Exhaust valves with less than 1.05 mm (3/64 inch) margin should be discarded. 3. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 4. Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator. Total runout should not exceed 0.051 mm (0.002 inch.) (total indicator reading). 5. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face, raise valve seat with a 65 degrees stone. - Intake valve seat diameter is 33 mm (1.299 inch.) - Exhaust valve seat diameter is 28 mm (1.102 inch.) Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. 6. When seat is properly positioned the width of intake and exhaust seats should be 0.9 to 1.3 mm (0.35 to 0.051 inch.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2000 7. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to 47.99 mm (1.889 in.) for exhaust valve and 48.04 mm (1.891 in.) for intake valve over spring seat when installed in the head. The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed. NOTEThis is not valve spring height measurement. See valve installation procedures for height measurement. REMOVAL 1. With cylinder head removed, compress valve springs using Special Tool MD 998735 or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. VALVE INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2001 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 39.20 mm (1.543 in.), install a .762 mm (0.030 inch.) spacer under the valve spring seat to bring spring height back within specification. 5. Install rocker arm shafts as previously described in this section. 6. Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. Specified dry lash is 1.17 mm (0.046 in.) for intake and 1.28 mm (0.050 in.) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster/s to bleed down before rotating cam. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 2011 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 2017 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2018 Drive Belt: Adjustments Fig. 42 Serpentine Drive Belt Routing 1. Loosen T-Bolt locking nut and pivot bolt to replace Poly V-belt and/or adjust belt tension. 2. Tighten adjusting bolt to adjust belt tension to specification shown in belt tension chart. 3. Tighten T-Bolt locking nut and pivot bolt to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner 105 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest: > 091294 > Jul > 94 > Engine Mount - Clicking Noise When Shifting Engine Mount: Customer Interest Engine Mount - Clicking Noise When Shifting NO: 09-12-94 GROUP: Engine DATE: Jul. 8, 1994 SUBJECT: Right Engine Mount Click Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE APRIL 30, 1994 (MDH 04-30-XX) SYMPTOM/CONDITION: Click sound coming from the right side of the engine compartment during garage shift maneuvers and/or engine torque changes during low road speed operation. DIAGNOSIS: To verify the condition: 1. Start the vehicle, set the parking brake, and apply the service brakes. 2. Operate the transmission shifter through a series of Reverse - Drive shifts and listen for the noise. 3. If the noise is evident, place a screwdriver or similar device between the outer bracket and the isolator shell (see Figure 1). 4. Again operate the transmission shifter through a series of Reverse - Drive shifts and listen for the noise. 5. If the noise is gone, proceed with the repair. 6. If the noise is still present, follow the Engine Diagnosis - Mechanical listed in the service manual and repair as required. PARTS REQUIRED: 1 4668432 Support Assembly - Engine Mounting - Rt. REPAIR PROCEDURE: This bulletin involves replacing the right engine mount bracket. 1. Remove the purge duty solenoid from the engine. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest: > 091294 > Jul > 94 > Engine Mount - Clicking Noise When Shifting > Page 2030 2. Remove the right engine mount insulator vertical fasteners from the frame (Figure 2). 3. Remove the load on the engine mounts by carefully supporting the engine and transmission assembly with a floor jack. 4. Remove the thru bolt from the insulator assembly (Figure 2). Remove the insulator. 5. Install right side engine mount P/N 4668432 by reversing the removal procedure. 6. Tighten the engine mount to frame rail fasteners to 54 N-M (40 ft.lbs.). Before tightening the thru bolt, be sure there is no load on the insulator. Tighten the thru bolt to 101 N-M (75 ft.lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-40-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 090596 > Mar > 96 > Engine - Excessive Perceived Movement Engine Mount: All Technical Service Bulletins Engine - Excessive Perceived Movement NO: 09-05-96 GROUP: Engine DATE: Mar. 22, 1996 SUBJECT: Excessive Engine Motion/Engine Mount Wear Characteristics MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Perceived excessive engine rolling during wide open throttle simulation and/or visible cracks in portions of engine mount rubber isolator. DISCUSSION: The perceived "excessive engine motion" is a design characteristic and is required to maintain adequate isolation of the powertrain noise/vibration from the passenger compartment. Some visible cracks in portions of the engine mount rubber isolator are also design characteristics. The rubber molding process allows excess rubber to fill in the areas around the mount legs. The excess rubber cracks due to the normal motion of the engine mount. The shading in figures 1 and 2 show the areas where cracks are allowable. The cracks do not affect the durability or function of the parts. THE ENGINE MOUNTS SHOULD NOT BE REPLACED FOR EITHER OF THE CONDITIONS DESCRIBED ABOVE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 090596 > Mar > 96 > Engine - Excessive Perceived Movement > Page 2036 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 091294 > Jul > 94 > Engine Mount - Clicking Noise When Shifting Engine Mount: All Technical Service Bulletins Engine Mount - Clicking Noise When Shifting NO: 09-12-94 GROUP: Engine DATE: Jul. 8, 1994 SUBJECT: Right Engine Mount Click Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE APRIL 30, 1994 (MDH 04-30-XX) SYMPTOM/CONDITION: Click sound coming from the right side of the engine compartment during garage shift maneuvers and/or engine torque changes during low road speed operation. DIAGNOSIS: To verify the condition: 1. Start the vehicle, set the parking brake, and apply the service brakes. 2. Operate the transmission shifter through a series of Reverse - Drive shifts and listen for the noise. 3. If the noise is evident, place a screwdriver or similar device between the outer bracket and the isolator shell (see Figure 1). 4. Again operate the transmission shifter through a series of Reverse - Drive shifts and listen for the noise. 5. If the noise is gone, proceed with the repair. 6. If the noise is still present, follow the Engine Diagnosis - Mechanical listed in the service manual and repair as required. PARTS REQUIRED: 1 4668432 Support Assembly - Engine Mounting - Rt. REPAIR PROCEDURE: This bulletin involves replacing the right engine mount bracket. 1. Remove the purge duty solenoid from the engine. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 091294 > Jul > 94 > Engine Mount - Clicking Noise When Shifting > Page 2041 2. Remove the right engine mount insulator vertical fasteners from the frame (Figure 2). 3. Remove the load on the engine mounts by carefully supporting the engine and transmission assembly with a floor jack. 4. Remove the thru bolt from the insulator assembly (Figure 2). Remove the insulator. 5. Install right side engine mount P/N 4668432 by reversing the removal procedure. 6. Tighten the engine mount to frame rail fasteners to 54 N-M (40 ft.lbs.). Before tightening the thru bolt, be sure there is no load on the insulator. Tighten the thru bolt to 101 N-M (75 ft.lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-40-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Tires: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2051 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2052 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2053 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2054 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2064 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2065 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2066 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Mount: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 2067 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2068 Engine Mount: Specifications Right Side Mount 40 ft.lb Left Side Mount 40 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2069 Engine Mount: Service and Repair FRONT 1. Support engine and transaxle with suitable floor jack. 2. Remove front engine mount through bolt from insulator and crossmember mounting bracket. 3. Remove mass damper, front mount nuts and insulator assembly. 4. Remove front mounting bracket 5. Reverse procedure for installtion and tighten fasteners in this order. a. Tighten bolt 1 to 3 Nm (20 in. lbs.) and bolts 2,3 and 4 to 108 Nm (80 ft. lbs.). b. Tighten bolts 5 and 1 to 54 Nm (40 ft. lbs.). c. Tighten unsulator assembly nuts to 54 Nm (40 ft. lbs.). d. Install mass damper and tighten tio 54 Nm (40 ft. lbs.). e. tighten thru bolt to 54 Nm (40 ft. lbs.). LEFT 1. Raise and support vehicle, then remove left front tire wheel assembly. 2. Remove power distribution center and place aside. 3. Support transaxle with suitable jack, then remove the insulator through bolt from mount. 4. Remove the transmission mount fasteners and remove mount. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2070 5. Reverse procedure for installation. Before tightening the thru-bolt be sure there is no load in the insulator. Tighten the thru bolt to 108 Nm (80 ft. lbs.). RIGHT 1. Remove purge duty solenoid from engine mount bracket. 2. Remove right engine mount insulator vertical fasteners from frame rail. 3. Carefully support engine/transaxle assembly to relieve pressure on mount. 4. Remove through bolt from insulator, then the insulator. 5. Reverse removal procedure for installtion. Tighten the engine mount to frame rail fasteners to 54 Nm (40 ft. lbs.) Before tightening the thru-bolt be sure there is no load on the insulator. Tighten the thru-bolt to 108 Nm (80 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications Oil Pressure Specifications Curb Idle: 25 kPa (4 psi) minimum 3000 RPM: 170-550 kPa (25-80 psi) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2076 Engine Oil: Capacity Specifications TYPE ................................................................................................................................................... ...................................................... SG or SG/CD [1] VISCOSITY Below 38° C (100° F) ........................................................................................................................... ............................................................ 5W-30 Above 38° C (100° F) .................................................. ................................................................................................................................... 10W-30 CAPACITY With filter .............................................................................................................................................. ............................................... 4.25 l (4.5 qts) Without filter ................................................................. ......................................................................................................................... 3.8 l (4.0 qts) [1] Energy Conserving II Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Oil Filter Application Change Oil Filter: Technical Service Bulletins Engine - Oil Filter Application Change NO: 09-03-96 GROUP: Engine DATE: Mar. 1, 1996 SUBJECT: 2.0L/2.4L Engine Oil Filter Application THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-95 DATED APR. 7, 1995 AND 09-15-95 DATED JUN. 30, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS INCLUDE ADDITIONAL MODELS AND ADDITIONAL INFORMATION IN THE DISCUSSION. MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager 1996 (GS) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L OR 2.4L ENGINE EXCEPT (FJ) AVENGER/SEBRING COUPE/TALON. DISCUSSION: Vehicles equipped with a 2.0L or 2.4L engine now have oil filter P/N 4105409 installed when shipped from the assembly plant. This oil filter is smaller in diameter and shorter than oil filter, P/N 5281090, commonly found on most Chrysler products. The smaller oil filter, P/N 4105409, is specified for the applications listed above to provide additional ground clearance. It should be used whenever a filter is changed, regardless of what filter was on the vehicle before service. Failure to use the correct oil filter may result in oil filter damage. The smaller oil filter, P/N 4105409, must be changed every time the oil is changed on all 2.4L engine equipped vehicles and 2.0L equipped JA and GS vehicles. Filter maintenance intervals have not changed for any other vehicles. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2081 Oil Filter: Service and Repair FILTER CAUTION: When servicing the oil filter avoid deforming the filter can by installing the removal install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair ADAPTER Ensure 0-ring is in the groove on adapter. Align roll pin into engine block and tighten assembly to 55 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2088 Oil Pan: Service and Repair 1. Drain engine oil into a suitable container, then remove the oil pan attaching bolts and pan. 2. Clean oil pan and all gasket surfaces. 3. Reverse procedure to install, noting the following: a. Apply Mopar silicone rubber adhesive sealant, or equivalent, at oil pump to engine block parting line and on oil pan gasket to hold gasket in place. b. Tighten pan bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation LOW OIL-PRESSURE LAMP The Low Oil-Pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit, which also powers the other warning lamps. When the oil pressure is low, the normally open oil pressure switch closes, completing a path to ground. The oil pressure switch is case-grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2098 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Fig. 3 Oil Pressure Switch Normal Operation The low oil pressure warning lamp will illuminate when the ignition key is turned to the ON position without engine running. The lamp also illuminates should the engine oil pressure drop below a safe oil pressure level. Low Oil Pressure Warning Lamp Test 1. To test the system turn ignition key to the ON position. - If the lamp lights circuit operation is normal. - If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, go to step 2. 2. Pull connector loose from the switch and with a jumper wire ground connector to the engine. 3. With the ignition key turned to the ON position check the warning lamp. - If lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications Oil Pump: Specifications Oil Pump Oil Pump Attaching Bolts 250 in.lb Cover Bolts 105 in.lb Pick Up Tube Screw 250 in.lb Relief Valve Retaining Cap 30 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Oil Pump Service Oil Pump: Service and Repair Oil Pump Service DISASSEMBLE 1. Remove relief valve plug and gasket, then the spring and relief valve. 2. Remove oil pump attaching bolts and cover. 3. Remove pump rotors. ASSEMBLE 1. Assemble pump using new parts as required. Install inner rotor with chamfer facing cast iron oil pump cover. 2. Apply Mopar gasket maker lightly to cover mounting surface on pump body. Attach cover and tighten to specifications. 3. Install relief valve, spring, gasket and cap and tighten to specifications. 4. Prime oil pump before installation by filling rotor cavity with clean engine oil. 5. Apply Mopar gasket maker to oil pump. Install oil-ring into counter bore on oil pump body discharge passage. 6. Install oil pump slowly onto crankshaft until seated to engine block. Tighten attaching bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Oil Pump Service > Page 2104 Oil Pump: Service and Repair Inspection DISASSEMBLE 1. Remove relief valve plug and gasket, then the spring and relief valve. 2. Remove oil pump attaching bolts and cover. 3. Remove pump rotors. INSPECTION 1. Clean all parts thoroughly in a suitable solvent. Mating surface of oil pump should be smooth. Replace pump cover if scratched or grooved. 2. Lay a straightedge across pump cover surface. If 0.003 inch feeler gauge can be inserted between cover and straightedge, replace cover. 3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 0.301 inch or less, or if diameter is 3.148 inches or less, replace outer rotor. 4. If inner rotor measures 0.301 inch or less, replace inner rotor. 5. Place outer rotor into pump housing and press to one side. Measure clearance between rotor and housing. If measurement is 0.015 inch or more, replace housing. 6. Install inner rotor into pump housing. If clearance between inner and outer rotors is 0.008 or more, replace rotors. 7. Place a straightedge across face of pump housing, between bolt holes. If a feeler gauge of 0.004 inch or more can be inserted between rotors and straightedge, replace pump assembly, only if rotors are in specification. 8. Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet/dry sandpaper. 9. Oil pump relief valve spring is approximately 2.39 inches in length and should indicate 18-19 lbs. resistance when compressed to 1.6 inches. Replace spring if it fails to meet specification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation NO: 09-09-97 GROUP: Engine DATE: Dec. 19, 1997 SUBJECT: Gasket Surface Preparation On Aluminum Engine Components MODELS: 1995 (AA) Acclaim/Spirit 1995 (AJ) Lebaron Convertible 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1998 (FJ) Avenger/Sebring/Talon 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1996 - 1998 (NS) Caravan/Voyager/Town & Country 1995 - 1998 (PL) Neon 1997 (PR) Prowler DISCUSSION: Many aluminum engine components are being received by the material return center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden scrapers are the only approved methods for removing gasket material. NOTE: DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR. Engine components received by the material return center will be evaluated for appropriate gasket removal procedures. Components returned with obvious damage caused by improper gasket removal procedures may be denied for warranty reimbursement. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2109 Intake Manifold: Specifications Intake Manifold Bolts/Nuts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2110 Intake Manifold: Service and Repair WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. Fig. 1 Fuel Pressure Test Port Fig. 2 Releasing Fuel Pressure FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 1). 4. Place open end of fuel pressure release hose tool No. C-4799-1, or equivalent, into a suitable gasoline container, then connect other hose end to fuel pressure test port. Fuel pressure should bleed off through hose into container. REMOVAL 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative battery cable. 3. Disconnect the fuel supply line quick connect at the fuel tube assembly. WARNING: Wrap shop towels around hose to catch any gasoline spillage. 4. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering. CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2111 Fig. 3 Fresh Air Duct To Throttle Body Assembly 5. Remove fresh air duct and upper air filter housing (Fig. 3) 6. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Fig. 4 Idle Air Control (IAC) Motor And Throttle Position Sensor (TPS) Wiring Connectors And Vacuum Hose Connection. 7. Disconnect Idle Air Control (IAC) motor and throttle position sensor (TPS) wiring connectors (Fig. 4). 8. Disconnect vacuum hoses from throttle body (Fig. 4). Fig. 5 Intake Manifold Electrical, Vacuum Hose Connections And Knock Sensor Electrical Connector 9. Disconnect Manifold Absolute Pressure (MAP), and intake air temperature electrical connectors. Disconnect vapor and brake booster hoses (Fig. 5). 10. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the intake manifold (Fig. 5). 11. Disconnect electrical connector from starter relay. 12. Remove transmission to throttle body support bracket fasteners at the throttle body and loosen fastener at transmission end. 13. Remove throttle body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2112 Fig. 6 EGR Tube Assembly 14. Remove EGR tube bolts at the valve and at the intake manifold (Fig. 6). Remove tube from engine. Fig. 8 Intake Manifold Tightening Sequence 15. Remove the intake manifold to inlet water tube support fastener (Fig. 8). 16. Remove 9 intake manifold screw and washer assemblies and 1 lock nut. Discard the fasteners. Remove intake manifold. Fig. 7 Intake Manifold O-rings INSPECTION Check for: Inspect manifold for cracks or distortions. - Check for torn or missing O-rings at the mating surface of the manifold (Fig. 7). NOTE: Before installing manifold. Clean all mating surfaces. Replace all seals, with new seals. All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used. INSTALLATION 1. Install intake manifold onto cylinder head and tighten fasteners to 11.9 N.m (105 in. lbs.) in sequence shown in (Fig. 8). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2113 2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.). 3. Connect PCV and brake booster hoses (Fig. 5). 4. Inspect quick connect fittings for damage, replace if necessary. Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly Check connection by pulling on connector to insure it locked into position. 5. Install throttle body Tighten fastener to 22 N.m (200 in. lbs.). Install transmission to throttle body support bracket and tighten to 11.9 N.m (105 in. lbs.) at the throttle body first. Next tighten the bracket at the transmission. 6. Connect manifold absolute pressure (MAP) and intake air temperature sensor wiring connectors (Fig. 5). 7. Connect knock sensor electrical and starter relay connectors. Connect wiring harness to intake manifold tab. 8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 4). 9. Connect vacuum hoses to throttle body (Fig. 4). 10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever. 11. Loosely assemble the EGR tube onto valve and intake manifold finger tight (Fig. 6). Tighten tube fasteners at the EGR valve first to 11 N.m (95 in. lbs. then, tighten the intake manifold side fasteners to 11 N.m (95 in. lbs.). 12. Install fresh air duct to air filter housing. Tighten clamp to 3 N.m (30 in. lbs.) (Fig. 3). 13. Connect negative battery cable. 14. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation LOW OIL-PRESSURE LAMP The Low Oil-Pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit, which also powers the other warning lamps. When the oil pressure is low, the normally open oil pressure switch closes, completing a path to ground. The oil pressure switch is case-grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2121 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Fig. 3 Oil Pressure Switch Normal Operation The low oil pressure warning lamp will illuminate when the ignition key is turned to the ON position without engine running. The lamp also illuminates should the engine oil pressure drop below a safe oil pressure level. Low Oil Pressure Warning Lamp Test 1. To test the system turn ignition key to the ON position. - If the lamp lights circuit operation is normal. - If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, go to step 2. 2. Pull connector loose from the switch and with a jumper wire ground connector to the engine. 3. With the ignition key turned to the ON position check the warning lamp. - If lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design Camshaft Oil Seal: Technical Service Bulletins Front Cam Seal Retainer - New Design NUMBER: 09-008-00 GROUP: Engine DATE: Jan. 12, 2001 SUBJECT: Front Cam Seal Retention OVERVIEW: This bulletin involves installation of a new component to assist cam seal retention. MODELS: NOTE: THIS INFORMATION APPLIES TO MODELS EQUIPPED WITH A 1.8 OR 2.0L SOHC ENGINE. DISCUSSION: A new cam seal retainer has been released to retain the front cam seal on 1.8L or 2.0L SOHC engines. Whenever a cam seal is replaced, a retainer should be installed to provide positive retention. PARTS REQUIRED: REPAIR PROCEDURE: 1. Upon engine re-assembly after front cam seal installation, install the retainer p/n 5016733AA using the inner cover fasteners as shown in (Fig. 1) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design > Page 2127 2. Torque the fasteners to 20 Nm (15 ft. lbs.). 3. Complete the re-assembly following the applicable service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Rear Crankshaft Seal - Service Procedure Crankshaft Main Bearing Seal: Technical Service Bulletins Rear Crankshaft Seal - Service Procedure NO: 09-06-95 GROUP: Engine DATE: Apr. 14, 1995 SUBJECT: Rear Crankshaft Seal Service Procedure MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Cirrus/Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC NON TURBO OR A 2.4L ENGINE. DISCUSSION: The following information is being provided as an interim repair procedure to service the crankshaft oil seal. A revised procedure including new special tools will be available with the 1996 new model launch. At that time, the affected 1995 Service Manuals will be revised to include the new procedure REPAIR PROCEDURE: This bulletin involves a procedure to remove and install the rear crankshaft oil seal. Figure 1. Rear Seal Removal 1. Pry out the rear seal with a screwdriver. Be careful not to nick or damage the crankshaft flange seal surface or retainer bore (Figure 1). 2. Crankshaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. Figure 2. Rear Seal Installation With Special Tool 3. Place Special Tool C-4681 on the crankshaft (Figure 2). NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Rear Crankshaft Seal - Service Procedure > Page 2132 A NEW REAR CRANKSHAFT SEAL IS NOT SUPPLIED WITH A SELF CONTAINED INSTALLATION SLEEVE AS NOTED IN EARLIER PROCEDURES. 4. Place seal over Special Tool C4681 such that the writing "THIS SIDE OUT" is visible on the seal. Lightly tap the new seal into place with a plastic hammer until the seal is just flush with the machined cylinder block surface. NOTE : IF THE SEAL IS INSTALLED UNDER FLUSH TO THE CYLINDER BLOCK THE SEAL LIP MAY FALL BEHIND THE CRANKSHAFT SEAL SURFACE RESULTING IN AN OIL LEAK. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 2133 Crankshaft Main Bearing Seal: Service and Repair 1. With transaxle separated from engine, pry out rear seal with screwdriver. Do not nick or damage crankshaft flange seal surface or retainer bore. 2. Inspect shaft seal surface for nicks or dirt. Polish with 400 grit sandpaper if necessary. 3. Reverse procedure to install, noting the following: a. Seal should be installed dry, with "THIS SIDE OUT" mark facing away from block. b. Use pilot tool No. 6926-1, seal installation tool No. 6926-2 and handle tool No. C-4171, or equivalents, to install seal. Do not drive seal beyond flush with block surface. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures Technical Service Bulletin # 09-08-99 Date: 990917 Multi Layer Steel Head Gasket - Installation Procedures NUMBER: 09-08-99 GROUP: Engine DATE: Sep. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-98, DATED NOV. 6, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE PART NUMBER REVISIONS AND MODEL ADDITIONS. SUBJECT: Multi-Layer Steel (MLS) Head Gasket Installation Procedures MODELS: **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - 2000 (JA) Cirrus/Stratus/Breeze 1996 - 2000 (JX) Sebring Convertible 1995-2000 (PL) Neon 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC (NATURALLY ASPIRATED) OR 2.4L ENGINE. DISCUSSION: Multi-Layer Steel (MLS) head gaskets have been developed and released for use on the above models. The MLS gasket was released for production, as a running change, in the 1999 model year for all models except FJ. This new gasket provides superior sealing characteristics, but will require extra care in their installation where a composite gasket was previously in place. The following steps outline the proper installation of this MLS gasket. CAUTION: ALUMINUM ENGINE COMPONENTS ARE SUSCEPTIBLE TO METAL TRANSFER AND SURFACE DAMAGE WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING GASKET MATERIAL FROM ALUMINUM COMPONENTS. THE MLS GASKET CANNOT PROPERLY SEAL IF GOUGING OF SURFACES, METAL TRANSFER, OR COMPOSITE GASKET MATERIAL IS LEFT ON THE HEAD OR BLOCK SURFACES. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 2138 PARTS REQUIRED: EQUIPMENT REQUIRED: 1 NPN Plastic/Wooden Scraper AR(1) 07528 2" 3M Roloc Bristle Disc White (For Aluminum Surfaces) AR(1) 07525 2" 3M Roloc Bristle Disc Yellow (For Aluminum/Cast Iron/Steel Surfaces) 1 05539 2" 3M Roloc Bristle Disc Arbor 1 NPN Drill Motor POLICY: Information Only. Repair Procedure This bulletin outlines the proper procedures for preparing head/block surfaces for MLS gasket installation. 1. Following service manual procedures, remove the head. 2. Remove as much of the loose composite gasket material with a plastic or wooden scraper. NOTE: PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT MAY BE NECESSARY IF EXCESSIVE PITTING OR EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE COOLING PASSAGES. 3. Cover coolant and oil passages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket material. 4. Using a plastic or wooden scraper, scrape the composite gasket residue from the surfaces. If necessary, apply additional solvent or gasket remover to ease removal. 5. If additional cleaning is needed, use a drill motor and 3M Roloc bristle disc p/n 07528 (white) to carefully remove the remaining gasket material from the head and block surfaces. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 2139 IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES TO PREVENT METAL TRANSFER. 6. Inspect the sealing surfaces for any remaining composite gasket residue. Carefully remove any remaining material. 7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable. 8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035. 9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torqueing procedures. All head bolts should be oiled prior to assembly. NOTE: THE 2.0L DOHC TORQUE AND TORQUING PROCEDURE HAS CHANGED WITH THE INSTALLATION OF A MLS GASKET. USE THE FOLLOWING PROCEDURES FOR THE 2.0L DOHC ONLY. 2.OL DOHC TORQUE PROCEDURE WITH MLS GASKET INSTALLATION NOTE: THE 4 SHORT BOLTS ARE PLACED IN THE CORNERS. A. Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolts to 27 Nm (20 Ft Lbs) see Fig 1 for torque sequence. B. Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. C. Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. D. Tighten all bolts in the specified sequence (Fig 1) an additional 90° (1/4 turn). 10. Make sure the cam sensor seal is replaced on all engine applications. NOTE: A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK. 11. Replace the engine oil and filter after performing these procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 2140 Cylinder Head Gasket: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Page 2141 Cylinder Head Gasket: Service and Repair CLEANING Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface. For removal and replacement SEE CYLINDER HEAD ASSEMBLY. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair FRONT SEAL REMOVAL 1. Using large side of Special Tool 1026 and Insert 6827, remove crankshaft damper. 2. Remove outer timing belt cover and timing belt. Refer to Timing Belt. 3. Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2. CAUTION: Do not nick shaft seal surface or seal bore. 4. Using Tool 6771 to remove front crankshaft oil seal. Be careful not to damage the seal surface of cover. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2145 1. Install new seal by using Tool 6780. 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. 3. Install crankshaft sprocket using Special Tool 6792. 4. Install timing belt and timing belt covers. Refer to Timing System Section for timing belt covers and belt. 5. Install crankshaft damper. Use thrust bearing/washer and 12M-1.75 x 150 mm bolt from Special Tool Kit 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair See Camshaft and Crankshaft timing proceduress. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair Timing Belt: Service and Repair TIMING BELT SERVICE VALVE TIMING CHECK-TIMING BELT COVER INSTALLED 1. Remove number one spark plug. 2. Using a dial indicator; set number one cylinder to TDC on the compression stroke. 3. Remove the access plug from the outer timing belt cover. 4. Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover. REMOVAL 1. Remove accessory drive belts. Refer to Cooling System for procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2160 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827. 4. Lower vehicle and place a jack under engine. 5. Remove right engine mount. 6. Remove right engine mount bracket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2161 7. Remove front half of timing belt cover. Caution: Align camshaft and crankshaft timing marks before removing the timing belt. 8. Loosen timing belt tensioner screws and remove timing belt and tensioner. SERVICING CAMSHAFT OIL SEALS/REPLACEMENT CAUTION: Do not rotate the camshaft of crankshaft when timing belt is removed, damage to the engine may occur. 1. With timing belt removed, remove camshaft sprocket bolt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2162 2. Modify Special Tool C-4687-1 as shown in image above. Hold camshaft sprocket with modified tool while removing/installing bolt. Remove sprocket from camshaft. 3. Remove camshaft seal using Special C-4679 . CAUTION: Do not nick shaft seal surface of bore. 4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. 5. Install camshaft seal flush with cylinder head using Special Tool MD 998306. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2163 6. Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tool C-4687-1 (shown in image above) and tighten bolt to 115 Nm (85 ft. lbs.). CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE TIMING BELT TENSIONER / TIMING BELT INSTALLATION 1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. 2. Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine. 3. When plunger is compressed into the tensioner body install a 1.9 mm (5/64) allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2164 4. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC. 5. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover. 6. Move crankshaft to 1/2 mark before TDC for belt installation. 7. Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket. 8. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2165 9. Using a torque wrench on the tensioner pulley apply 28 Nm (250 in. lbs.) of torque. 10. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 in. lbs.). 11. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 13. Install front half of timing cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 2166 14. Install engine mount bracket. 15. Install Right engine mount. 16. Remove jack from under engine. 17. Install crankshaft damper using M12-1.75 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt an tighten to 142 Nm (105 ft. lbs.). 18. Install accessory drive belts. Refer to Cooling System and Accessory Drive for procedure. 19. Raise vehicle on hoist and install right inner splash shield. 20. Perform relearn camshaft and crankshaft alignment procedure in Engine Miscellaneous of the DRB Scan Tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Tensioner Pivot Bracket Assembly - Service Timing Belt Tensioner: Technical Service Bulletins Tensioner Pivot Bracket Assembly - Service NO: 09-06-96 GROUP: Engine DATE: Mar. 29, 1996 SUBJECT: Tensioner Pivot Bracket Assembly Service MODELS: 1995 - 1996 (FJ) Avenger, Sebring, Talon 1995 - 1996 (JA) Cirrus, Stratus, Breeze 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH A 2.0L SOHC OR DOHC ENGINE. DISCUSSION: The following information is in addition to the repair procedure found in the appropriate Service Manual, Group 9, camshaft and crankshaft timing procedure and belt installation section. The tensioner pivot bolt should never be tightened, loosened or removed. The bolt is installed at the manufacturer with a loctite adhesive that is not reusable. If the tensioner pivot bolt is disturbed, the entire pivot bracket assembly (P/N 4777346) must be replaced. See illustration. The pulley fastener that holds the pulley to the pivot bracket may be removed and reinstalled. It should then be torqued to 50 ft. lbs. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Page 2171 Timing Belt Tensioner: Specifications Timing Belt Timing Belt Tensioner 275 in.lb Tesioner Pivot Bracket Ass. 275 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2175 Timing Cover: Service and Repair 1. Remove accessory drive belts. 2. Raise and support vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt, then remove damper using puller tool No. 1023 and insert tool No. C-4685-C2, or equivalents. 4. Lower vehicle and place jack under engine. 5. Remove right engine mount and bracket. 6. Remove front half of timing belt cover. 7. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 1 Air Cleaner AIR CLEANER Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. The air cleaner attaches to a bracket on the rear of the cylinder head (Fig. 1). An ambient air duct supplies underhood air for the engine. FILTER ELEMENT REPLACEMENT 1. Unfasten clasps of front of air cleaner lid. Lift lid off of air cleaner housing. 2. Remove clean air duct from throttle body. 3. Remove make-up air hose. Fig. 2 Air Cleaner Housing And Element 4. Remove filter element (Fig. 2). 5. If necessary, clean the inside of the air cleaner housing. 6. Install new filter element. 7. Place lid over air cleaner housing. Snap clasps over the air cleaner lid. 8. Install clean air duct to throttle body CAUTION: DO NOT Over Torque Air Cleaner Housing Cover Clamps. 9. Tighten air cleaner cover clamps to (15-25 in lb). 10. Install make-up air hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2192 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2203 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2206 Ignition Cable: Component Tests and General Diagnostics Testing Fig. 4 Setting Spark Plug Electrode Gap TESTING USING AN OSCILLOSCOPE When testing cables for punctures and cracks with an oscilloscope, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during test or possible heat damage to catalytic converter will occur. Total test time must not exceed one minute. NOTE: Test must be performed at idle only. IF AN OSCILLOSCOPE IS NOT AVAILABLE, TEST CABLES AS FOLLOWS: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Cracked, leaking or faulty cables should be replaced. 3. Use an ohmmeter to check cables for opens, loose terminals or high resistance. a. Remove cable from spark plug. b. Remove cable from the coil tower. c. Connect the ohmmeter between spark plug end terminal and the coil end terminal. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in same manner. CABLE RESISTANCE CHART MINIMUM MAXIMUM 250 Ohms/Inch 1,000 Ohms/Inch 3,000 Ohms/Foot 12,000 Ohms/Foot Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2207 Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 2210 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. On SOHC engines, be sure that dual plastic clip holds #1, #2 cables off of valve cover and that PCV hose plastic clip holds #3 cable away from metal PCV clamp and edge of air duct. On DOHC, be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 2215 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2218 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2219 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2220 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2221 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2224 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2225 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2226 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2227 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2228 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2229 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2230 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2231 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2232 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2233 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2243 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 2249 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 2250 Coolant: Specifications Coolant Capacity [04] .......................................................................................................................... ....................................................................... 7.4 qts Radiator Cap Relief Pressure .............................................................................................................. ......................................................................... 16 psi Thermo. Opening Temp. ..................................................................................................................... ........................................................................ 195 °F Fuel Tank ............................................................................................................................................. ....................................................................... 11 gals Engine Oil Refill [03] ............................................................................................................................ ...................................................................... 4.5 qts Auto. Transaxle Oil [02] ....................................................................................................................... ........................................................................... [01] Man. Transaxle Oil .............................................................................................................................. ............................................................... 4.0 - 4.6 pts [01] Oil change only ............................................................................................................................. ................................................................... 4.0 qts. After overhaul: except fleet models ............................................................................................................................................................. 8.9 qts. fleet models ............................................................................................................................ ............................................ 9.2 qts. [02] Approximate capacity. Make final inspection with dipstick. [03] Includes oil filter. [04] Includes heater and coolant recovery system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 2260 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 2266 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2275 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2276 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2282 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2283 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Fan Motor to Shroud Retaining Screws (A/C Equipped) 3.8 Nm 34 In Lbs Fan Motor to Shroud Retaining Screws (non A/C Equipped) 2.3 Nm 20 In Lbs Fan Module (Shroud) to Radiator Fasteners 7.3 Nm 65 In Lbs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Radiator Cooling Fan Motor: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Air Conditioning-Heater (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Air Conditioning-Heater (Part 2 Of 2) The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Cooling Fan Modules Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation Radiator Cooling Fan Motor: Description and Operation Circuit Operation Cooling Fan Modules Circuit Operation The radiator fan system used in this vehicle uses one relay located in the Power Distribution Center (PDC). Power for the coil side of the relay is supplied on circuit F12. This circuit is HOT in the START and RUN position and protected by a 15 Amp fuse located in cavity 10 of the fuse block. Power for the fuse is supplied on circuit A21 from the ignition switch. Power for the A21 circuit is supplied by circuit A1 from the PDC. The A1 circuit is protected by a 30 Amp fuse in the PDC. Power for the contact side of the relay is supplied on circuit A16. This circuit is HOT at all times and protected by a 30 Amp fuse located in the PDC. Ground for the coil side of the relay is controlled by the Powertrain Control Module (PCM). When the PCM determines the need for fan operation the PCM supplies the ground path for circuit C27. This circuit connects to cavity 55 of the PCM connector. This causes the contacts in the relay to CLOSE connecting circuits A16 and C25. The C25 circuit connects to the radiator fan motor. Ground for the motor is supplied on circuit Z1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 2310 Radiator Cooling Fan Motor: Description and Operation Cooling Fan Motor Description Cooling Fan Modules All models use single speed electric motor driven cooling system fan(s). The fan module(s) includes a motor, fan blade, and support shroud. The module is fastened to the radiator by screws. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 2311 Radiator Cooling Fan Motor: Description and Operation Radiator Fan Control Cooling Fan Modules Fan control is accomplished in two ways. The fan always runs when the compressor clutch is engaged. - The fan is also turned on by the temperature of the coolant which is sensed by the coolant temperature sensor. The coolant temperature sensor sends this signal to the engine controller which turns the fan on through the fan relay. Switching through the engine controller provides fan control for the following conditions: 1. Fan will not run when cranking engine no matter what coolant temperature is. 2. Fan will run when A/C clutch engaged and low pressure cutout switch is closed. 3. At vehicle speeds over 40 mph, fan will run only if coolant temperature reaches 230°F (110°C) and fan will turn off when temperature drops to 220°F (104°C). 4. At vehicle speeds under 40 mph, fan will run when coolant temperature reaches 215°F (102°C) and fan will turn off when temperature drops 200° F (93°C). 5. To prevent steaming, the fan will run with engine at idle speed and only for three minutes, when ambient temperature is below 60°F (16°C) and coolant temperature is between 100-207°F (38-97°C). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Inoperative Radiator Cooling Fan Motor: Testing and Inspection Fan Motor Inoperative Note: This procedure has been updated by TSB 070197 Dated 03/28/97. Radiator fans are not operating. Visually inspect the RFI connector and RFI filter module for signs of damage. (See Illustration) - If damage is found proceed to RFI Repair Procedure. See: Service and Repair Cooling System Diagnosis - If no damage is found, proceed to cooling system diagnosis. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Inoperative > Page 2314 Radiator Cooling Fan Motor: Testing and Inspection Radiator Fan Motor Disconnect fan motor electrical connector, then connect a 14 gauge jumper wire from battery positive terminal to fan motor terminal. If fan motor does not operate normally, replace fan motor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Blade Radiator Cooling Fan Motor: Service and Repair Fan Blade The fan blade cannot be repaired in any way. Warpage, cracking or other damage can only be remedied by blade replacement. To remove from motor shaft, proceed as follows: 1. Support motor and shaft. Failure to do so may result in damage from excessive force. 2. Remove retaining clip from front of shaft, then draw fan blade off shaft. It may be necessary to eliminate burrs from shaft prior to blade removal. 3. Reverse procedure to install. Ensure motor and shaft are supported during fan blade retaining clip installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Blade > Page 2317 Radiator Cooling Fan Motor: Service and Repair Fan Motor Assembly (Module) WARNING: Do not disassemble the fan motor from the support bracket. NOTE: Electric fan motor is serviced as an assembly with the fan module. REMOVAL 1. Disconnect fan motor leads from module. Servicing Fan Module 2. Remove fan module fasteners from radiator. INSTALLATION 1. Install module to radiator. Torque shroud to radiator fasteners to 7.3 Nm (65 inch lbs.). 2. Connect fan motor lead. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Blade > Page 2318 Radiator Cooling Fan Motor: Service and Repair RFI Repair Procedure Note: This procedure has been updated by TSB 070197 Dated 03/28/97. Parts Required: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor Repair Procedure: Note: This procedure involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. Referring to instructions and following all warnings. Remove and set aside: radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assembly face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute tubing. 8. Stagger cut the two wires on the wire harness side approximately 2 1/2 inches apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1 inch. 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1 inch. 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assembly, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2 1/2 inches apart. NOTE: Cut the wires away from the one-to-two wire splices. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Blade > Page 2319 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1 1/2 inches behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 In. Lbs.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 In. Lbs.) Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. Referring to instructions and following all warnings. Install: upper radiator mounts - battery tray - battery - battery thermo-guard - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 In. Lbs.) and battery terminals to 7.2 Nm (65 In. Lbs.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2323 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2324 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Radiator Fan Relay: Connector Views Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Air Conditioning-Heater (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Air Conditioning-Heater (Part 2 Of 2) The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 2349 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Control Relay Circuit NAME OF CODE: High Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the high speed radiator fan relay control circuit. THEORY OF OPERATION: The high speed radiator fan relay controls the high speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Low Speed Fan Control Relay Circuit NAME OF CODE: Low Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the low speed radiator fan relay control circuit. THEORY OF OPERATION: The low speed radiator fan relay controls the low speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Rad Fan Control Relay Circuit NAME OF CODE: Rad Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 2350 SET CONDITION: An open or shorted condition is detected in the radiator fan relay control circuit. THEORY OF OPERATION: The radiator fan relay controls the operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. When the engine coolant temperature has reached the maximum temperature parameter, the relay will be grounded. Conversely, when the engine coolant temperature has acquired the minimum temperature parameter, the relay will remove the ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Low speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Fan Relay: Initial Inspection and Diagnostic Overview - Check the 30 Amp maxi fuse located in the Power Distribution center (PDC) for the radiator fan motor(s). - Check the 15 Amp fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor clutch relays. - Check the 10 Amp micro fuse located in the power distribution center. When checking the A/C compressor clutch relay, - Check the 25 Amp fuse located in cavity 7 of the fuse block when checking blower motor operation, - Check the right headlamp ground located at the right fender side shield. - Check the left headlamp ground located on the left side of the radiator closure panel. - On vehicles equipped with A/C, check the refrigerant level. The system will not operate with a low level of refrigerant. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2358 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2359 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2360 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2361 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 2383 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2386 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2387 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAUGE The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM), and the other side for the instrument cluster. The sending unit is case grounded to the engine. The gauge uses two coils, and the current passing through the coils creates a magnetic field. Movement of the needle is determined by the amount of current passing through the coils to ground at the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test Temperature Gauge: Testing and Inspection Temperature Gauge Test Fig. 6 Engine Coolant Temperature Sensor 1. Disconnect temperature sending unit. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF. 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp go out, the cluster should chime for about eight seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, the high temperature chime sounds but the gauge shows cold. Replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test > Page 2397 Temperature Gauge: Testing and Inspection Sending Unit Test 1. Sending units and wiring can be checked by grounding the connector leads, at the sending unit, in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Page 2398 Temperature Gauge: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair 1. Disconnect battery ground cable. 2. Drain cooling system, then remove hose clamps from radiator. 3. Disconnect automatic transaxle hoses from cooler and plug off. 4. Remove radiator to battery strut, then fan module assembly by disconnecting fan motor electrical connector. 5. Remove fan shroud retaining screws located on top of shroud. 6. Lift shroud up and out of bottom shroud attachment clips separating shroud from radiator. 7. On models equipped with dual cooling fans, the left fan module may be removed first, then the right side module. 8. On all models, remove upper radiator isolator bracket mounting screws, then the engine block heater, if equipped. 9. Remove air conditioning condenser attaching screws located at front of radiator, if equipped. Do not discharge air conditioning system. 10. Remove radiator from engine compartment by lifting upward. 11. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2411 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2412 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2418 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 2419 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2423 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2424 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 Radiator Fan Relay: Connector Views Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 Air Conditioning-Heater (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Air Conditioning-Heater (Part 2 Of 2) The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 2449 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Control Relay Circuit NAME OF CODE: High Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the high speed radiator fan relay control circuit. THEORY OF OPERATION: The high speed radiator fan relay controls the high speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Low Speed Fan Control Relay Circuit NAME OF CODE: Low Speed Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the low speed radiator fan relay control circuit. THEORY OF OPERATION: The low speed radiator fan relay controls the low speed operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in PCM Rad Fan Control Relay Circuit NAME OF CODE: Rad Fan Control Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 2450 SET CONDITION: An open or shorted condition is detected in the radiator fan relay control circuit. THEORY OF OPERATION: The radiator fan relay controls the operation of the radiator fan. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant temperature. When the engine coolant temperature has reached the maximum temperature parameter, the relay will be grounded. Conversely, when the engine coolant temperature has acquired the minimum temperature parameter, the relay will remove the ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Low speed radiator fan relay control circuit open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Fan Relay: Initial Inspection and Diagnostic Overview - Check the 30 Amp maxi fuse located in the Power Distribution center (PDC) for the radiator fan motor(s). - Check the 15 Amp fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor clutch relays. - Check the 10 Amp micro fuse located in the power distribution center. When checking the A/C compressor clutch relay, - Check the 25 Amp fuse located in cavity 7 of the fuse block when checking blower motor operation, - Check the right headlamp ground located at the right fender side shield. - Check the left headlamp ground located on the left side of the radiator closure panel. - On vehicles equipped with A/C, check the refrigerant level. The system will not operate with a low level of refrigerant. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 2462 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 2468 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2474 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2475 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2476 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2477 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 2499 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2502 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2503 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAUGE The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM), and the other side for the instrument cluster. The sending unit is case grounded to the engine. The gauge uses two coils, and the current passing through the coils creates a magnetic field. Movement of the needle is determined by the amount of current passing through the coils to ground at the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test Temperature Gauge: Testing and Inspection Temperature Gauge Test Fig. 6 Engine Coolant Temperature Sensor 1. Disconnect temperature sending unit. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF. 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp go out, the cluster should chime for about eight seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, the high temperature chime sounds but the gauge shows cold. Replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test > Page 2509 Temperature Gauge: Testing and Inspection Sending Unit Test 1. Sending units and wiring can be checked by grounding the connector leads, at the sending unit, in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Page 2510 Temperature Gauge: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. 2. Remove Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts. 3. Remove thermostat assembly, and clean sealing surfaces. INSTALLATION 1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head. 2. Install thermostat housing/outlet connector onto cylinder head and tighten bolts to 12.5 Nm (110 inch lbs.). Connect the CRS hose. 3. Refill cooling system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2517 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Mounting Bolts 23 Nm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation Fig. 9 Exhaust Manifold REMOVAL 1. Remove air cleaner assembly and bracket. 2. Remove exhaust manifold heat shield. 3. Remove exhaust pipe from manifold. 4. Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold. CLEANING AND INSPECTION 1. Discard gasket and clean all gasket surfaces of manifolds and cylinder head. 2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. 3. Inspect manifolds for cracks or distortion. Replace manifold if necessary. INSTALLATION 1. Set exhaust manifold in place. Apply Loctite 277 or equivalent to fasteners and tighten to 23 N.m (200 in. lbs.) starting at center and progressing outward in both directions. Repeat this procedure until all fasteners are at specified torque. 2. Install exhaust manifold heat shield. 3. Install air cleaner bracket and assembly. 4. Attach exhaust pipe and tighten fasteners to 28 N.m (250 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 2528 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING AND INSPECTION 1. Discard gasket and clean all gasket surfaces of manifolds and cylinder head. 2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. 3. Inspect manifolds for cracks or distortion. Replace manifold if necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 110494A > Oct > 94 > Exhaust - Hissing & Puffing Noises Exhaust Pipe: Customer Interest Exhaust - Hissing & Puffing Noises NO: 11-04-94 Rev. A GROUP: Exhaust DATE: Oct. 28, 1994 SUBJECT: Exhaust Noise THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-94 DATED JUL. 1, 1994 WHICH SHOULD BE REMOVE FROM YOUR FILES. THIS BULLETIN ADDS PARTS AND ADDITIONAL CONDITION AND FAILURE CODES. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 24, 1994, MDH (04-24-XX). SYMPTOM/CONDITION: Exhaust noise that can be described as a "hissing" or "puffing" sound on acceleration or under moderate to heavy engine load, coming from the front of the vehicle. **And/or a squeak/chirp noise may be heard on engine start up or shut down or when shifting gears.** PARTS REQUIRED: **1 4546818 Exhaust Seal Ring** **2 4427299 Exhaust Flange Springs** REPAIR PROCEDURE: This bulletin involves **replacement of the exhaust seal ring and exhaust flange springs** and sizing of the catalytic converter inlet pipe to provide a better fit of the exhaust seal ring. 1. Raise the vehicle on hoist and disconnect the downstream oxygen sensor connector. 2. Remove the two shoulder bolts, springs and nuts retaining the front catalytic converter pipe to the exhaust manifold. **Discard old springs.** 3. Loosen the clamp between the catalytic converter and the intermediate exhaust pipe and remove the catalytic converter from the vehicle. **4. Replace the seal ring with revised P/N 4546818.** 5. With the seal ring in place on the catalytic converter inlet pipe, use a manual multisegment pipe expander to round-up the inlet pipe diameter of the catalyst so that the seal ring is "snug" to the pipe. The seal ring should still rotate on the pipe, but not spin freely. Expand only the first 13 mm (approx. 1/2") of the inlet pipe. NOTE: BE CAREFUL NOT TO EXPAND THE PIPE TOO FAR AS THE SEAL RING COULD CRACK. SHOULD THE SEAL RING CRACK, BOTH THE CATALYTIC CONVERTER AND SEAL RING WILL HAVE TO BE REPLACED. A HYDRAULIC PIPE EXPANDER IS NOT RECOMMENDED FOR THIS PROCEDURE. 6. Install the catalytic converter to the vehicle and install the inlet pipe to the exhaust manifold, **using new springs, P/N 4427299.** 7. Connect the downstream oxygen sensor connector. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-20-05-93 0.5 Hrs. FAILURE CODE: **EN - Exhaust Noise or SX - Seal Squeak** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 110494A > Oct > 94 > Exhaust - Hissing & Puffing Noises Exhaust Pipe: All Technical Service Bulletins Exhaust - Hissing & Puffing Noises NO: 11-04-94 Rev. A GROUP: Exhaust DATE: Oct. 28, 1994 SUBJECT: Exhaust Noise THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-94 DATED JUL. 1, 1994 WHICH SHOULD BE REMOVE FROM YOUR FILES. THIS BULLETIN ADDS PARTS AND ADDITIONAL CONDITION AND FAILURE CODES. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 24, 1994, MDH (04-24-XX). SYMPTOM/CONDITION: Exhaust noise that can be described as a "hissing" or "puffing" sound on acceleration or under moderate to heavy engine load, coming from the front of the vehicle. **And/or a squeak/chirp noise may be heard on engine start up or shut down or when shifting gears.** PARTS REQUIRED: **1 4546818 Exhaust Seal Ring** **2 4427299 Exhaust Flange Springs** REPAIR PROCEDURE: This bulletin involves **replacement of the exhaust seal ring and exhaust flange springs** and sizing of the catalytic converter inlet pipe to provide a better fit of the exhaust seal ring. 1. Raise the vehicle on hoist and disconnect the downstream oxygen sensor connector. 2. Remove the two shoulder bolts, springs and nuts retaining the front catalytic converter pipe to the exhaust manifold. **Discard old springs.** 3. Loosen the clamp between the catalytic converter and the intermediate exhaust pipe and remove the catalytic converter from the vehicle. **4. Replace the seal ring with revised P/N 4546818.** 5. With the seal ring in place on the catalytic converter inlet pipe, use a manual multisegment pipe expander to round-up the inlet pipe diameter of the catalyst so that the seal ring is "snug" to the pipe. The seal ring should still rotate on the pipe, but not spin freely. Expand only the first 13 mm (approx. 1/2") of the inlet pipe. NOTE: BE CAREFUL NOT TO EXPAND THE PIPE TOO FAR AS THE SEAL RING COULD CRACK. SHOULD THE SEAL RING CRACK, BOTH THE CATALYTIC CONVERTER AND SEAL RING WILL HAVE TO BE REPLACED. A HYDRAULIC PIPE EXPANDER IS NOT RECOMMENDED FOR THIS PROCEDURE. 6. Install the catalytic converter to the vehicle and install the inlet pipe to the exhaust manifold, **using new springs, P/N 4427299.** 7. Connect the downstream oxygen sensor connector. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-20-05-93 0.5 Hrs. FAILURE CODE: **EN - Exhaust Noise or SX - Seal Squeak** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 2542 Exhaust Pipe: Specifications Heat Shield Mounting Screws ............................................................................................................. ........................................................... 4 Nm (35 in lb) Catalytic Converter to Exhaust Pipe Saddle Clamp ...................................................................................................................................... 22 Nm (30 ft lb) Exhaust Pipe to Muffler Saddle Clamp ......................................................................................................................................................... 31 Nm (23 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 2543 Exhaust Pipe: Service and Repair Fig. 5 Slip Joint Connection - Typical EXHAUST PIPE AND MUFFLERS REMOVAL 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed Fig. 6 Exhaust Pipe And Muffler Support Insulators 2. Remove clamp and supports at muffler. Remove muffler from exhaust pipe. Fig. 7 Catalytic Converter To Exhaust Pipe Connection 3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 2544 4. Remove clamp at the catalytic converter to exhaust pipe slip joint. Separate at slip joint. 5. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms. Fig. 8 Catalytic Converter To Exhaust Manifold Connection 6. Remove catalytic converter to exhaust manifold attaching bolts. 7. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; To insure proper alignment with other parts in the system. - Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. INSTALLATION 1. Assemble catalytic convertor to exhaust manifold ball joint connection. 2. Assemble exhaust pipe to catalytic convertor and the support to the underbody. 3. Install the muffler to exhaust pipe and the sup- ports to the underbody. 4. Working from the front of system; a. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts. Fig. 9 Exhaust Clearance b. Align each component to maintain position and proper clearance with underbody parts and tighten clamps to specifications. 5. Connect the downstream heated oxygen sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2553 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2554 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2560 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2561 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration > Page 2570 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration > Page 2571 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2577 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 2578 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Catalytic Converter to Exhaust Pipe Saddle Clamp ...................................................................................................................................... 22 Nm (30 ft lb) Exhaust Pipe to Muffler Saddle Clamp ......................................................................................................................................................... 31 Nm (23 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2582 Muffler: Service and Repair Fig. 5 Slip Joint Connection - Typical EXHAUST PIPE AND MUFFLERS REMOVAL 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed Fig. 6 Exhaust Pipe And Muffler Support Insulators 2. Remove clamp and supports at muffler. Remove muffler from exhaust pipe. Fig. 7 Catalytic Converter To Exhaust Pipe Connection 3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2583 4. Remove clamp at the catalytic converter to exhaust pipe slip joint. Separate at slip joint. 5. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms. Fig. 8 Catalytic Converter To Exhaust Manifold Connection 6. Remove catalytic converter to exhaust manifold attaching bolts. 7. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; To insure proper alignment with other parts in the system. - Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. INSTALLATION 1. Assemble catalytic convertor to exhaust manifold ball joint connection. 2. Assemble exhaust pipe to catalytic convertor and the support to the underbody. 3. Install the muffler to exhaust pipe and the sup- ports to the underbody. 4. Working from the front of system; a. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts. Fig. 9 Exhaust Clearance b. Align each component to maintain position and proper clearance with underbody parts and tighten clamps to specifications. 5. Connect the downstream heated oxygen sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: Recalls Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: Recalls Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2599 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2600 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2601 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2607 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2608 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: Customer Interest PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 2613 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 2618 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2624 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2625 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 2630 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 2635 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2644 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2645 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2646 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2652 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 2653 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 2658 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 2663 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2673 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2674 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 2675 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2676 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2677 Fig. 2 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 Powertrain Control Module: Electrical Diagrams Wiring Diagrams For Information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams 5 Volt Supply Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2698 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation Powertrain Control Module: Description and Operation PCM Operation Fig. 2 Powertrain Control Module (PCM) Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 2701 - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 2702 Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 2703 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Battery Feed Operation BATTERY FEED Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 11 of the powertrain control module (PCM). A 20 amp micro fuse in the PDC protects circuit A14. Internal Controller Failure NAME OF CODE: Internal Controller Failure WHEN MONITORED: With the ignition ON. SET CONDITION: There is an Eraseable Programable Read Only Memory (EPROM) sum check failure at power down. THEORY OF OPERATION: This code indicates the EPROM memory may be corrupt. POSSIBLE CAUSES: - Failed Powertrain Control Module (PCM) PCM Failure EEPROM Write Denied NAME OF CODE: PCM Failure EEPROM Write Denied WHEN MONITORED: With the ignition ON, SBEC tries to write to EEPROM memory. SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus PCM Failure SPI Communications NAME OF CODE: PCM Failure SPI Communications WHEN MONITORED: With the ignition ON. SET CONDITION: Serial communications inside the controller fail eight times during a run cycle. THEORY OF OPERATION: Communications between microprocessors inside the Powertrain Control Module (PCM) are needed to operate the total system. If failure occurs, the solenoids and relays may not actuate properly. POSSIBLE CAUSES: - PCM failure PCM Failure SRI Mile Not Stored NAME OF CODE: PCM Failure SRI Mile Not Stored WHEN MONITORED: With the ignition ON SBEC tries to write service reminder indicator mileage to EEPROM memory. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 2704 SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus 5 Volt Supply Output Too Low NAME OF CODE: 5 Volt supply Output Too Low WHEN MONITORED: With the ignition ON. SET CONDITION: The 5 volt supply to the sensors is below 3.5 volts for 4 seconds. THEORY OF OPERATION: The PCM maintains a 5 volt supply to the MAP sensor, Throttle Position (TP) sensor, and A/C pressure sensor. It is critical that the 5 volt supply stays between 4.8 and 5.1 volts as this input has a direct effect on sensor output voltages. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut-Down (ASD) relay and fuel pump relay. The A14 circuit also splices to the data link connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2707 Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) PCM 60 Way Connector Checks Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2708 Powertrain Control Module 60-Way Connector Check the powertrain control module (PCM) 60-way connector for: Spread terminals - Stretched or pulled out wires - Moisture or corrosion - Under-tightened or over-tightened 60 way connector Tighten the PCM connector to 4 Nm (35 in lb) torque. When checking terminal pinouts, refer to the Powertrain Control Module 60-Way Connector Diagram for circuit wire colors and cavity numbers. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2709 Powertrain Control Module: Service and Repair Fig. 21 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 21). REMOVAL 1. Disconnect negative cable from battery 2. Remove screws attaching PCM to body 3. Lift PCM up. Disconnect PCM 60-way connector. 4. Remove PCM. INSTALLATION 1. Attach 60-way connector to PCM. Tighten 60-way connector screw to 4.5 Nm (40 in lb) torque. 2. Install PCM. Tighten mounting screws to 9 Nm (80 in lb) torque. 3. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 2734 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 2735 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 2736 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 2737 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel pump relay is located in the power distribution center, at the lefthand side of the engine compartment and behind the battery. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2754 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2755 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Fuel Pump Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2761 Fuel Pump Relay: Description and Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2762 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2763 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2770 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 2788 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 2789 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 2790 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 2791 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2798 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2799 Absolute Pressure Sensor: Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2803 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 2806 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2815 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2816 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2833 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2834 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2835 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2838 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2839 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2840 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2843 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2844 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 2845 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2850 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 2851 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2852 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2853 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 2875 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2878 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2879 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2883 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 2905 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 2906 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 2907 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 2908 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 2909 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2912 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 2913 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor Torque ....................................................................................................................................................... 10 Nm (90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2917 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Intake Air Temperature Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Intake Air Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor-PCM Input Fig. 4 Intake Air Temperature Sensor And MAP Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the intake air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse width and spark advance. The IAT sensor threads into the intake manifold (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 2939 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation Fig. 16 Intake Air Temperature Sensor And MAP Sensor PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 6 of the PCM, and cavity 1 of the sensor connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 2940 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High NAME OF CODE: Intake Air Temp Sensor Voltage High WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes above 4.9 volts. THEORY OF OPERATION: The Intake Air Temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 2941 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low NAME OF CODE: Intake Air Temp Sensor Voltage Low WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes below 0.157 volt. THEORY OF OPERATION: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2944 Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 28 Intake Air Temperature Sensor 1. With the key off, disconnect wire harness connector from the intake air temperature sensor (Fig. 28). 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 6 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2945 Intake Air Temperature Sensor: Service and Repair Fig. 10 Intake Air Temperature Sensor And MAP Sensor NOTE: The intake air temperature sensor threads into the intake manifold plenum (Fig. 10). REMOVAL 1. Remove engine cover. 2. Disconnect electrical connector from sensor. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Install engine cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 2949 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 2969 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 2972 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2977 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2978 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 Manifold Pressure/Vacuum Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 Manifold Absolute Pressure Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Operation Fig. 4 Intake Air Temperature Sensor And MAP Sensor The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately - As vacuum decreases, MAP sensor voltage increases proportionately Key ON At key ON -- during cranking, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. Engine Running While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP sensor mounts to the intake manifold (Fig. 4). CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 29 of the PCM, and cavity 3 of the MAP connector. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 3000 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: The MAP sensor is a semiconductor type sensor. This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Signal circuit open - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM MAP Sensor Voltage Too Low NAME OF CODE: MAP Sensor Voltage Too Low WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The Manifold Absolute Pressure (MAP) sensor signal voltage is below 1.2 volts at start, or below 0.2 volt for 1.76 seconds with engine running. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - Failed PCM No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition ON and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 3001 high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM No 5 Volts to MAP Sensor NAME OF CODE: No 5 Volts to MAP Sensor WHEN MONITORED: With the ignition OFF. SET CONDITION: The MAP sensor signal voltage goes below 1.96 volts. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5 volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. - The MAP receives a 5 volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - MAP sensor failure TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 3004 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Refer to Group 14 for Manifold Absolute Pressure (MAP) sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 3005 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 17 Intake Air Temperature Sensor And MAP Sensor NOTE: The MAP sensor attaches to the intake manifold plenum (Fig. 17). REMOVAL 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions Oxygen Sensor: Technical Service Bulletins Engine Controls/Electrical - Manual Revisions NUMBER: 08-32-94 GROUP: Electrical DATE: Jul. 15, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon Service Manual Supplement - Publication No. 81-270-5025A DESCRIPTION OF CHANGES O2 Sensor K42 Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3010 8W-30-16 Eliminate Alternate Cavity 15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3011 8W-80-8 Eliminate Alternate Cavity 2 On Connector C142 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3012 8W-80-15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3013 Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3016 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3017 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3029 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3031 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3032 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3033 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3034 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 Oxygen Sensor: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 Oxygen Sensors Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3037 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description Oxygen Sensor: Description and Operation Oxygen Sensor Description Downstream Oxygen Sensor Fig. 13 Downstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Upstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3040 Fig. 12 Upstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. OPERATION The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. - When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Heating Element The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. - Also, it allows the system to remain in closed loop operation during periods of extended idle. Closed Loop Operation In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. Open Loop Operation In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3041 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure NAME OF CODE: Downstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the PCM powers up the sensor heater. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Downstream O2 Sensor Shorted to Ground NAME OF CODE: Downstream O2S Shorted To Ground WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: The downstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage NAME OF CODE: Downstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The downstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3042 and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Downstream O2 Sensor Slow Response NAME OF CODE: Downstream O2 Sensor Slow Response WHEN MONITORED: With the vehicle engine temperature greater than 170° F and engine speed over 1,600 rpm. Rich response test is conducted when at WOT, with the front O2 sensor indicating a rich F/A condition. Lean response test is conducted when at closed throttle, in decel fuel shut-off (except SOHC automatic transmission vehicles), and with the front O2 sensor indicating a lean F/A condition. SET CONDITION: The rich response test will fail if the downstream O2 sensor voltage is less than 0.60 volts within 5 seconds of meeting the test conditions. The lean response test will fail if the downstream voltage is greater than 0.29 volts within 5 seconds of meeting the test conditions. The trouble code will be set if either (or both) tests fail three times per trip. Once the rich and lean response test each pass once, the testing is complete that trip. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Exhaust leak - Fuel contamination - Electrical wiring connectors - Engine mechanical Downstream O2 Sensor Stays at Center NAME OF CODE: Downstream O2 Sensor Stays at Center WHEN MONITORED: With the vehicle engine running for over 2 minutes, temperature greater than 170° F, in closed loop. SET CONDITION: With oxygen sensor voltage staying between 0.39 volts and 0.52 volts during the trip, the PCM pulls the sensor voltage to 5.0 volts for 30 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Sensor output wire open - Electrical wiring connectors - Open ground circuit - PCM failure - Oxygen sensor failure O2S Stays Above Center (Rich) NAME OF CODE: O2S Stays Above Center (Rich) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3043 WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays between 0.5 and 1.2 volts without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - High fuel pressure - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem O2S Stays Below Center (Lean) NAME OF CODE: O2S Stays Below Center (Lean) WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays below 0.5 without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Low fuel pressure - Vacuum Leak - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem Upstream O2 Sensor Heater Failure NAME OF CODE: Upstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the Powertrain Control Module (PCM) powers up the sensor heater. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3044 the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Upstream O2 Sensor Shorted to Ground NAME OF CODE: Upstream O2 Sensor Voltage Shorted to Ground WHEN MONITORED: With the ignition key off, after the engine cools down. SET CONDITION: The upstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals - Connector wires Upstream O2 Sensor Shorted to Voltage NAME OF CODE: Upstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The upstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The Powertrain Control Module (PCM) receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Upstream O2 Sensor Slow Response NAME OF CODE: Upstream O2S Response WHEN MONITORED: With the engine running for more than 3 minutes, engine temperature greater than 170° F, after reaching a vehicle speed of 24 MPH, at idle with Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3045 the transmission in drive (auto) or in neutral (manual). SET CONDITION: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300-350° C (572-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. POSSIBLE CAUSES: - Exhaust leak - Fuel contamination Upstream O2 Sensor Stays at Center NAME OF CODE: Upstream O2S Stays at Center WHEN MONITORED: With the engine running for more than 2 minutes and engine temperature greater than 170° F. SET CONDITION: The upstream oxygen sensor signal voltage is 0.5 volts for 1.5 minutes. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire open - O2 sensor failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3046 Oxygen Sensor: Testing and Inspection NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3049 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3050 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3059 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3065 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3070 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3071 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3072 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3073 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3078 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3079 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3080 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3081 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3087 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3088 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3089 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3090 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3095 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3096 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3097 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 3098 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 3101 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 3102 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 3124 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3133 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3139 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3142 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3143 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3165 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3166 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3169 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3170 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3171 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3193 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 3204 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 3210 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vehicle Speed Sensor: > 141394 > Jul > 94 > Idle Air Control Motor - Whistle Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Idle Air Control Motor - Whistle Noise NO: 14-13-94 GROUP: Fuel DATE: Jul. 1, 1994 SUBJECT: Idle Air Control Motor Whistle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 1, 1994 (MDH 06-01-XX). SYMPTOM/CONDITION: A high-pitched whistling noise from the engine compartment is noticeable at idle. The noise may be more prevalent when the engine is idling in gear and under a load; such as air conditioning, or headlamps on. No whistling noise can be heard while cruising. DIAGNOSIS: Place the gear selector in park or neutral, set the parking brake and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Listen for the whistle noise. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. PARTS REQUIRED: 1 4796503 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Following the procedures outlined in the 1995 Neon Service Manual, Publication No. 81-270-5025 pages 14-45 and 14-46, replace the idle air control motor with new motor P/N 4796503. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-30-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3221 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Vehicle Speed Sensor: Electrical Diagrams Complete System Diagram For wiring Diagrams, refer to Powertrain Management/Diagrams/Electrical. See: Diagrams/Electrical Diagrams Vehicle Speed Sensor Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 180°F. SET CONDITION: No signal from the vehicle speed sensor (TCM) is present for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor is a hall effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. - The PCM supplies 8 volts from cavity 44 to power up the sensor. - Sensor ground is supplied by PCM cavity 51. - The PCM also supplies a 5.0 volt pull up voltage to the sensor from cavity 5. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion damaged - Open 8 volt supply circuit - Open sensor circuit ground - Failed speed sensor - PCM failure - Connector Terminals/Wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal > Page 3243 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 3244 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 3245 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 7 Nm (60 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3255 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3261 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3264 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3265 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3287 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3288 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3291 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3292 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3293 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3301 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3302 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3324 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3325 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3326 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3329 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3330 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 3331 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3335 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3353 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3354 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3357 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3358 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3359 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3360 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3361 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3364 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 3365 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 3370 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3371 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3372 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 3376 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 3396 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 3399 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 1 Air Cleaner AIR CLEANER Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. The air cleaner attaches to a bracket on the rear of the cylinder head (Fig. 1). An ambient air duct supplies underhood air for the engine. FILTER ELEMENT REPLACEMENT 1. Unfasten clasps of front of air cleaner lid. Lift lid off of air cleaner housing. 2. Remove clean air duct from throttle body. 3. Remove make-up air hose. Fig. 2 Air Cleaner Housing And Element 4. Remove filter element (Fig. 2). 5. If necessary, clean the inside of the air cleaner housing. 6. Install new filter element. 7. Place lid over air cleaner housing. Snap clasps over the air cleaner lid. 8. Install clean air duct to throttle body CAUTION: DO NOT Over Torque Air Cleaner Housing Cover Clamps. 9. Tighten air cleaner cover clamps to (15-25 in lb). 10. Install make-up air hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3416 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 3427 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3430 Ignition Cable: Component Tests and General Diagnostics Testing Fig. 4 Setting Spark Plug Electrode Gap TESTING USING AN OSCILLOSCOPE When testing cables for punctures and cracks with an oscilloscope, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during test or possible heat damage to catalytic converter will occur. Total test time must not exceed one minute. NOTE: Test must be performed at idle only. IF AN OSCILLOSCOPE IS NOT AVAILABLE, TEST CABLES AS FOLLOWS: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Cracked, leaking or faulty cables should be replaced. 3. Use an ohmmeter to check cables for opens, loose terminals or high resistance. a. Remove cable from spark plug. b. Remove cable from the coil tower. c. Connect the ohmmeter between spark plug end terminal and the coil end terminal. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in same manner. CABLE RESISTANCE CHART MINIMUM MAXIMUM 250 Ohms/Inch 1,000 Ohms/Inch 3,000 Ohms/Foot 12,000 Ohms/Foot Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3431 Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 3434 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. On SOHC engines, be sure that dual plastic clip holds #1, #2 cables off of valve cover and that PCV hose plastic clip holds #3 cable away from metal PCV clamp and edge of air duct. On DOHC, be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 3439 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 3442 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 3443 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3444 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3445 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3448 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3449 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3450 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3451 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3452 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3453 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3454 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3455 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 3456 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 3457 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 3469 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 3470 Absolute Pressure Sensor: Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions A/C Signal: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 A/C Signal: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 A/C Clutch Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output A/C Signal: Description and Operation A/C Clutch Relay -- PCM Output Fig. 19 Power Distribution Center (PDC) OPERATION The PCM controls the air conditioning clutch relay ground circuit. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and power side of the relay. When the PCM receives an air conditioning input, it grounds the A/C compressor clutch relay and the radiator fan relay. When the PCM senses low idle speeds or wide open throttle through the throttle position sensor, it removes the ground for the A/C compressor clutch relay. When the relay de-energizes, the contacts open preventing air conditioning clutch engagement. Also, if the PCM senses a part throttle launch condition, it disables the A/C compressor clutch for several seconds. The air conditioning clutch relay is located in the PDC (Fig. 19). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 3494 A/C Signal: Description and Operation Air Conditioning Request -- PCM Input The A/C compressor clutch relay controls the 12-volt source for the A/C clutch. The relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. - The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When the air conditioning or defrost switch is put in the ON position and the low pressure, A/C cycling, and high pressure switches are closed, the PCM receives an A/C input. After receiving this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The PCM adjusts idle air flow through Idle Air Control (IAC) motor -- compensating for increased engine load -- to maintain the scheduled RPM. The PCM grounds the relay control circuit after receiving an A/C select signal and adjustment of the idle speed has been implemented. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 3495 A/C Signal: Description and Operation Related Trouble Code Message Descriptions A/C Clutch Relay Circuit NAME OF CODE: A/C Clutch Relay Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the A/C clutch relay control circuit. THEORY OF OPERATION: The A/C compressor clutch relay controls the 12-volt source for the A/C clutch. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM will adjust the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C select signal and adjustment of the idle speed has been implemented. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in powertrain control module No 5 Volts to A/C Pressure Sensor NAME OF CODE: No 5 Volts to A/C Pressure Sensor WHEN MONITORED: With the ignition ON. SET CONDITION: The A/C pressure sensor signal at PCM cavity 42 goes below 0.705 volts for more than 21.97 seconds THEORY OF OPERATION: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. - If the system pressure is too high, the PCM will disengage the compressor clutch and turn ON the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5 volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - A/C pressure sensor failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor Torque ....................................................................................................................................................... 10 Nm (90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3499 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 Intake Air Temperature Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 Intake Air Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor-PCM Input Fig. 4 Intake Air Temperature Sensor And MAP Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the intake air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse width and spark advance. The IAT sensor threads into the intake manifold (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 3521 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation Fig. 16 Intake Air Temperature Sensor And MAP Sensor PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 6 of the PCM, and cavity 1 of the sensor connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 3522 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High NAME OF CODE: Intake Air Temp Sensor Voltage High WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes above 4.9 volts. THEORY OF OPERATION: The Intake Air Temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 3523 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low NAME OF CODE: Intake Air Temp Sensor Voltage Low WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes below 0.157 volt. THEORY OF OPERATION: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3526 Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 28 Intake Air Temperature Sensor 1. With the key off, disconnect wire harness connector from the intake air temperature sensor (Fig. 28). 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 6 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 3527 Intake Air Temperature Sensor: Service and Repair Fig. 10 Intake Air Temperature Sensor And MAP Sensor NOTE: The intake air temperature sensor threads into the intake manifold plenum (Fig. 10). REMOVAL 1. Remove engine cover. 2. Disconnect electrical connector from sensor. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Install engine cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 141394 > Jul > 94 > Idle Air Control Motor - Whistle Noise Auxiliary Air Valve (Idle Speed): Customer Interest Idle Air Control Motor - Whistle Noise NO: 14-13-94 GROUP: Fuel DATE: Jul. 1, 1994 SUBJECT: Idle Air Control Motor Whistle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 1, 1994 (MDH 06-01-XX). SYMPTOM/CONDITION: A high-pitched whistling noise from the engine compartment is noticeable at idle. The noise may be more prevalent when the engine is idling in gear and under a load; such as air conditioning, or headlamps on. No whistling noise can be heard while cruising. DIAGNOSIS: Place the gear selector in park or neutral, set the parking brake and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Listen for the whistle noise. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. PARTS REQUIRED: 1 4796503 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Following the procedures outlined in the 1995 Neon Service Manual, Publication No. 81-270-5025 pages 14-45 and 14-46, replace the idle air control motor with new motor P/N 4796503. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-30-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 141394 > Jul > 94 > Idle Air Control Motor - Whistle Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Idle Air Control Motor - Whistle Noise NO: 14-13-94 GROUP: Fuel DATE: Jul. 1, 1994 SUBJECT: Idle Air Control Motor Whistle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 1, 1994 (MDH 06-01-XX). SYMPTOM/CONDITION: A high-pitched whistling noise from the engine compartment is noticeable at idle. The noise may be more prevalent when the engine is idling in gear and under a load; such as air conditioning, or headlamps on. No whistling noise can be heard while cruising. DIAGNOSIS: Place the gear selector in park or neutral, set the parking brake and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Listen for the whistle noise. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. PARTS REQUIRED: 1 4796503 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Following the procedures outlined in the 1995 Neon Service Manual, Publication No. 81-270-5025 pages 14-45 and 14-46, replace the idle air control motor with new motor P/N 4796503. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-30-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3544 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 3547 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 3553 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 3554 Brake Signal: Description and Operation PURPOSE When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. The brake switch is mounted on the brake pedal support bracket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3561 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3562 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3584 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3585 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3586 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3589 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3590 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 3591 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 3596 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 3597 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3598 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3599 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 3621 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3624 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 3625 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3629 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3651 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3652 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3653 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3654 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 3655 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3658 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 3659 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Fig. 3 Data Link Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3663 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3664 Data Link Connector: Description and Operation Fig. 3 Data Link Connector PURPOSE Communication link to Powertrain Control Module (PCM) Technician can access inputs and memory including: - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Technician can actuate most PCM output devices. NOTE: Monitoring inputs, reading memory -- other than codes -- and actuating output devices can only be accomplished through the use of a scan tool. SEE TESTING AND INSPECTION. DATA LINK CIRCUITS The data link connector contains 16 terminals. Terminal 6 is the Data Link Engine Receive circuit. - Terminal 7 is the Data Link Engine Transmit (K-Line) circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation Electric EGR Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Page 3668 Electric EGR Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: Recalls Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall Powertrain Control module Powertrain Control Module: Recalls Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall Powertrain Control module > Page 3681 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall Powertrain Control module > Page 3682 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall Powertrain Control module > Page 3683 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3689 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3690 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: Customer Interest PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 3695 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3700 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3706 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3707 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 3712 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3717 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3726 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3727 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3728 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3734 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 3735 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 3740 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3745 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3755 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3756 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 3757 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3758 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3759 Fig. 2 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 Powertrain Control Module: Electrical Diagrams Wiring Diagrams For Information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams 5 Volt Supply Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3780 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation Powertrain Control Module: Description and Operation PCM Operation Fig. 2 Powertrain Control Module (PCM) Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 3783 - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 3784 Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 3785 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Battery Feed Operation BATTERY FEED Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 11 of the powertrain control module (PCM). A 20 amp micro fuse in the PDC protects circuit A14. Internal Controller Failure NAME OF CODE: Internal Controller Failure WHEN MONITORED: With the ignition ON. SET CONDITION: There is an Eraseable Programable Read Only Memory (EPROM) sum check failure at power down. THEORY OF OPERATION: This code indicates the EPROM memory may be corrupt. POSSIBLE CAUSES: - Failed Powertrain Control Module (PCM) PCM Failure EEPROM Write Denied NAME OF CODE: PCM Failure EEPROM Write Denied WHEN MONITORED: With the ignition ON, SBEC tries to write to EEPROM memory. SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus PCM Failure SPI Communications NAME OF CODE: PCM Failure SPI Communications WHEN MONITORED: With the ignition ON. SET CONDITION: Serial communications inside the controller fail eight times during a run cycle. THEORY OF OPERATION: Communications between microprocessors inside the Powertrain Control Module (PCM) are needed to operate the total system. If failure occurs, the solenoids and relays may not actuate properly. POSSIBLE CAUSES: - PCM failure PCM Failure SRI Mile Not Stored NAME OF CODE: PCM Failure SRI Mile Not Stored WHEN MONITORED: With the ignition ON SBEC tries to write service reminder indicator mileage to EEPROM memory. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 3786 SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus 5 Volt Supply Output Too Low NAME OF CODE: 5 Volt supply Output Too Low WHEN MONITORED: With the ignition ON. SET CONDITION: The 5 volt supply to the sensors is below 3.5 volts for 4 seconds. THEORY OF OPERATION: The PCM maintains a 5 volt supply to the MAP sensor, Throttle Position (TP) sensor, and A/C pressure sensor. It is critical that the 5 volt supply stays between 4.8 and 5.1 volts as this input has a direct effect on sensor output voltages. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut-Down (ASD) relay and fuel pump relay. The A14 circuit also splices to the data link connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3789 Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) PCM 60 Way Connector Checks Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3790 Check the powertrain control module (PCM) 60-way connector for: - Spread terminals - Stretched or pulled out wires - Moisture or corrosion - Under-tightened or over-tightened 60 way connector Tighten the PCM connector to 4 Nm (35 in lb) torque. When checking terminal pinouts, refer to the Powertrain Control Module 60-Way Connector Diagram for circuit wire colors and cavity numbers. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 3791 Powertrain Control Module: Service and Repair Fig. 21 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 21). REMOVAL 1. Disconnect negative cable from battery 2. Remove screws attaching PCM to body 3. Lift PCM up. Disconnect PCM 60-way connector. 4. Remove PCM. INSTALLATION 1. Attach 60-way connector to PCM. Tighten 60-way connector screw to 4.5 Nm (40 in lb) torque. 2. Install PCM. Tighten mounting screws to 9 Nm (80 in lb) torque. 3. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor Torque = 3 Nm (25 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3795 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Idle Air Control Motor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Motor Operation NAME OF CODE: Idle Air Control Motor Circuits WHEN MONITORED: With the ignition ON, battery voltage greater than 10.0 volts, and the idle air control motor (IAC) active. SET CONDITION: The Powertrain Control Module (PCM) senses a short to ground or battery voltage on any of the four IAC driver circuits for 2.75 seconds while the IAC motor is active. THEORY OF OPERATION: The idle air control motor is used by the PCM to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. POSSIBLE CAUSES: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor NOTE: The PCM cannot detect an open driver circuit or a stuck motor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation > Page 3817 Idle Speed/Throttle Actuator - Electronic: Description and Operation Target Idle Not Reached (+/200 RPM) NAME OF CODE: Target Idle Not Reached (+/- 200 RPM) WHEN MONITORED: Engine idling and the brake ON. There must not be a manifold absolute pressure (MAP) sensor trouble code or a throttle position sensor trouble code. SET CONDITION: Engine idle is not within 200 RPM of target idle for 2.96 milliseconds. THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. POSSIBLE CAUSES: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor - Carbon deposits - Driver circuit open Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation > Page 3818 Idle Speed/Throttle Actuator - Electronic: Description and Operation Vacuum Leak Found (IAC Fully Seated) NAME OF CODE: Vacuum Leak Found (IAC Fully Seated) WHEN MONITORED: With the engine running. SET CONDITION: The MAP sensor signal does not correlate to the TP sensor signal. THEORY OF OPERATION: The PCM monitors the MAP signal as well as the TP sensor signal. The vacuum reading decreases as throttle opening increases proportionally. The PCM compares the two values to verify the relation between the two signals. POSSIBLE CAUSES: - Vacuum Leak - Faulty MAP sensor - Faulty TP sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3819 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 14 Throttle Position Sensor And Idle Air Control Motor NOTE: The idle air control motor attaches to the side of the throttle body (Fig. 14). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body. Refer to procedure. 4. Remove idle air control motor mounting screws. 5. Remove idle air control motor. Ensure 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB or equivalent AIS Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 3 Nm (25 in lb) torque. 4. Install throttle body. Refer to procedure. 5. Attach electrical connectors to idle air control motor and throttle position sensor. 6. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service Precautions > Technician Safety Information Information Bus: Technician Safety Information - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. - Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service Precautions > Technician Safety Information > Page 3825 Information Bus: Vehicle Damage Warnings - Make sure the ignition is OFF before disconnecting any control module. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail due to corrosion. - Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Application and ID > Glossary of Terms Information Bus: Application and ID Glossary of Terms ACM - Air Bag Control Module ATC - Automatic Temperature Control BCM - Body Control Module CAB - Controller-Antilock Brake CCD - Chrysler Collision Detection (vehicle communications bus) EIC - Electronic Instrument Cluster MIC - Mechanical Instrument Cluster PCM - Powertrain Control Module TCM - Transmission Control Module VTSS - Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Application and ID > Glossary of Terms > Page 3828 Information Bus: Application and ID Vehicle Body Code ID CARS AA Chrysler LeBaron (4-door), Dodge Spirit, Plymouth Acclaim AC Chrysler New Yorker Salon, Dodge Dynasty AG Dodge Daytona AJ Chrysler LeBaron (2-door) AP Dodge Shadow, Plymouth Sundance AS Chrysler Town and Country, Dodge Caravan and Grand Caravan, Plymouth Voyager and Grand Voyager AY Chrysler Imperial, Chrysler Fifth Avenue FJ22 Chrysler Sebring Dodge Avenger FJ24 Eagle Talon JA Chrysler Cirrus Plymouth Cirrus Dodge Stratus LH Chrysler Concorde Chrysler, LHS, Chrysler New Yorker, Dodge Intrepid, Eagle Vision PL Dodge Neon, Plymouth Neon SR Dodge Viper TRUCKS AB Dodge Ram (Van / Wagon) 150, 250, 350 AD Dodge Ram (Pickup) 150, 250, 350 Dodge Ramcharger AN Dodge Dakota BR Dodge Ram (Pickup) 1500, 2500, 3500 BT Dodge Ram (Cab) 1500, 2500, 3500 ES Chrysler Grand Voyager, Chrysler Ram Van MJ Jeep Comanche XJ Jeep Cherokee YJ Jeep Wrangler ZJ Jeep Grand Cherokee Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus Information Bus: Description and Operation CCD Bus PURPOSE: The CCD bus relays information about the operation of vehicle components and circuits to the appropriate module(s). OPERATION The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD bus). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The CCD Bus may be used for communication between the Vehicle Theft Alarm (VTA) module, instrument panel, scan tool, and the Powertrain Control Module (PCM). The CCD Bus is both an input and output from the Vehicle Theft Alarm (VTA) module. Circuit D1 is used for CCD (+) and circuit D2 is used for CCD (-). These circuits are connected in with the data link connector and the Powertrain Control Module (PCM). Bus Information is Coded The CCD bus receives and delivers coded information between the modules. The information is coded to identify the message as well as the importance of the message. - When there are multiple messages trying to access the CCD bus at one time, the message with higher priority is allowed to access the bus first. Twisted Pair CCD bus consists of a twisted pair of wires that run from one module to another. The two wires (D1) and (D2) of the twisted pair that make up the CCD multiplex system are called "bus +", (bus plus) and "bus -", (bus minus) respectively. - Each wire has a measurable voltage level of roughly 2.5 volts. Voltage Divider Network Bias and Termination In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network." This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus+ and bus- at 2.5 volts. - Termination in the circuitry is required to complete the voltage divider network and also to provide some electromagnetic protection for the bus. NOTE: Modules using the CCD bus can be identified by accessing them through the CCD bus using a scan tool with the correct connector and cartridge. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus > Page 3831 Information Bus: Description and Operation Modules Connected to Body Control Module Some of the instructions tell you to disconnect a module that may not be available on this vehicle. Above is a matrix of modules and bodies showing the modules each vehicle is equipped with. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus > Page 3832 Information Bus: Description and Operation No CCD Message From Body Control Module NAME OF CODE: No CCD Message From Body Control Module WHEN MONITORED: Anytime the ignition is ON. SET CONDITION: No CCD messages are received from the BCM for 30 seconds. THEORY OF OPERATION: The PCM and BCM communicate across the CCD bus system. Information is needed from either module to operate their respective systems. POSSIBLE CAUSES: - Open CCD Bus (+) or (-) circuit between the modules. - BCM not powered up - BCM or PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus > Page 3833 Information Bus: Description and Operation No CCD Messages From TCM NAME OF CODE: No CCD Message From Transmission Control Module (TCM). WHEN MONITORED: Anytime the ignition is ON. SET CONDITION: No CCD messages are received from the TCM for 10 seconds. THEORY OF OPERATION: The PCM and TCM communicate across the CCD bus system. Information is needed from either module to operate their respective systems. POSSIBLE CAUSES: - Open CCD Bus (+) or (-) circuit between the modules. - TCM not powered up - TCM failure - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics Information Bus: Component Tests and General Diagnostics Diagnostic Strategies NOTE: Use these procedures only when instructed to do so by another test procedure. TIP: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. CAUTION: Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. Component Testing Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3836 Information Bus: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and connector - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 3840 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 3860 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 3863 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 3888 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 3889 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 3890 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 3891 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CHECK ENGINE (MALFUNCTION INDICATOR LAMP) The Check Engine lamp (Malfunction Indicator lamp) illuminates when the ignition switch is in the ON position, and prior to starting the vehicle. The lamp turns off after the vehicle is started. If, while the vehicle is running, a problem is detected in the engine control system, the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 3899 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3900 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 Manifold Pressure/Vacuum Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Manifold Absolute Pressure Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Operation Fig. 4 Intake Air Temperature Sensor And MAP Sensor The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately - As vacuum decreases, MAP sensor voltage increases proportionately Key ON At key ON -- during cranking, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. Engine Running While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP sensor mounts to the intake manifold (Fig. 4). CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 29 of the PCM, and cavity 3 of the MAP connector. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 3922 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: The MAP sensor is a semiconductor type sensor. This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Signal circuit open - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM MAP Sensor Voltage Too Low NAME OF CODE: MAP Sensor Voltage Too Low WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The Manifold Absolute Pressure (MAP) sensor signal voltage is below 1.2 volts at start, or below 0.2 volt for 1.76 seconds with engine running. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - Failed PCM No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition ON and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 3923 high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM No 5 Volts to MAP Sensor NAME OF CODE: No 5 Volts to MAP Sensor WHEN MONITORED: With the ignition OFF. SET CONDITION: The MAP sensor signal voltage goes below 1.96 volts. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5 volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. - The MAP receives a 5 volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - MAP sensor failure TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 3926 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Refer to Group 14 for Manifold Absolute Pressure (MAP) sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 3927 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 17 Intake Air Temperature Sensor And MAP Sensor NOTE: The MAP sensor attaches to the intake manifold plenum (Fig. 17). REMOVAL 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions Oxygen Sensor: Technical Service Bulletins Engine Controls/Electrical - Manual Revisions NUMBER: 08-32-94 GROUP: Electrical DATE: Jul. 15, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon Service Manual Supplement - Publication No. 81-270-5025A DESCRIPTION OF CHANGES O2 Sensor K42 Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3932 8W-30-16 Eliminate Alternate Cavity 15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3933 8W-80-8 Eliminate Alternate Cavity 2 On Connector C142 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 3934 8W-80-15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3935 Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3938 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3939 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 Oxygen Sensor: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 Oxygen Sensors Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3959 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description Oxygen Sensor: Description and Operation Oxygen Sensor Description Downstream Oxygen Sensor Fig. 13 Downstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Upstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3962 Fig. 12 Upstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. OPERATION The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. - When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Heating Element The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. - Also, it allows the system to remain in closed loop operation during periods of extended idle. Closed Loop Operation In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. Open Loop Operation In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3963 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure NAME OF CODE: Downstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the PCM powers up the sensor heater. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Downstream O2 Sensor Shorted to Ground NAME OF CODE: Downstream O2S Shorted To Ground WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: The downstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage NAME OF CODE: Downstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The downstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3964 and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Downstream O2 Sensor Slow Response NAME OF CODE: Downstream O2 Sensor Slow Response WHEN MONITORED: With the vehicle engine temperature greater than 170° F and engine speed over 1,600 rpm. Rich response test is conducted when at WOT, with the front O2 sensor indicating a rich F/A condition. Lean response test is conducted when at closed throttle, in decel fuel shut-off (except SOHC automatic transmission vehicles), and with the front O2 sensor indicating a lean F/A condition. SET CONDITION: The rich response test will fail if the downstream O2 sensor voltage is less than 0.60 volts within 5 seconds of meeting the test conditions. The lean response test will fail if the downstream voltage is greater than 0.29 volts within 5 seconds of meeting the test conditions. The trouble code will be set if either (or both) tests fail three times per trip. Once the rich and lean response test each pass once, the testing is complete that trip. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Exhaust leak - Fuel contamination - Electrical wiring connectors - Engine mechanical Downstream O2 Sensor Stays at Center NAME OF CODE: Downstream O2 Sensor Stays at Center WHEN MONITORED: With the vehicle engine running for over 2 minutes, temperature greater than 170° F, in closed loop. SET CONDITION: With oxygen sensor voltage staying between 0.39 volts and 0.52 volts during the trip, the PCM pulls the sensor voltage to 5.0 volts for 30 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Sensor output wire open - Electrical wiring connectors - Open ground circuit - PCM failure - Oxygen sensor failure O2S Stays Above Center (Rich) NAME OF CODE: O2S Stays Above Center (Rich) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3965 WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays between 0.5 and 1.2 volts without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - High fuel pressure - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem O2S Stays Below Center (Lean) NAME OF CODE: O2S Stays Below Center (Lean) WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays below 0.5 without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Low fuel pressure - Vacuum Leak - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem Upstream O2 Sensor Heater Failure NAME OF CODE: Upstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the Powertrain Control Module (PCM) powers up the sensor heater. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3966 the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Upstream O2 Sensor Shorted to Ground NAME OF CODE: Upstream O2 Sensor Voltage Shorted to Ground WHEN MONITORED: With the ignition key off, after the engine cools down. SET CONDITION: The upstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals - Connector wires Upstream O2 Sensor Shorted to Voltage NAME OF CODE: Upstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The upstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The Powertrain Control Module (PCM) receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Upstream O2 Sensor Slow Response NAME OF CODE: Upstream O2S Response WHEN MONITORED: With the engine running for more than 3 minutes, engine temperature greater than 170° F, after reaching a vehicle speed of 24 MPH, at idle with Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 3967 the transmission in drive (auto) or in neutral (manual). SET CONDITION: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300-350° C (572-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. POSSIBLE CAUSES: - Exhaust leak - Fuel contamination Upstream O2 Sensor Stays at Center NAME OF CODE: Upstream O2S Stays at Center WHEN MONITORED: With the engine running for more than 2 minutes and engine temperature greater than 170° F. SET CONDITION: The upstream oxygen sensor signal voltage is 0.5 volts for 1.5 minutes. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire open - O2 sensor failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3968 Oxygen Sensor: Testing and Inspection NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3971 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3972 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3981 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 3987 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3992 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3993 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3994 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 3995 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4000 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4001 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4002 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4003 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4009 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4010 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4011 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4012 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4017 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4018 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4019 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4020 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4023 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 4024 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 4046 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: Recalls Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module Powertrain Control Module: Recalls Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 4060 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 4061 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 614 > Feb > 94 > Recall - Powertrain Control module > Page 4062 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4068 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4069 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: Customer Interest PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181894 > Sep > 94 > PCM - Engine Sags, Hesitates, Surge/Occasional Shudder > Page 4074 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 4079 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4085 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4086 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder > Page 4091 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set > Page 4096 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4105 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4106 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4107 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4113 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 4114 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder Powertrain Control Module: All Technical Service Bulletins PCM - Engine Sags, Hesitates, Surge/Occasional Shudder NO: 18-18-94 GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Sags, Hesitation, Surge, and/or Occasional Shudder MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUG. 5, 1994 (MDH 08-05-XX). SYMPTOM/CONDITION: Sags, hesitation, surge and/or occasional engine shudder. The symptoms listed, depending on vehicle operation, may occur at different road speeds (highway/city traffic), throttle position (vehicle speeding up/slowing down), or may be encountered when various accessories or loads are applied. DISCUSSION: The diagnosis and repair procedures should be followed on all vehicles with the listed symptom/condition. However, this repair procedure will not affect normally occurring changes in engine power that occur on vehicles with air conditioning. When A/C is selected, the compressor cycles to prevent evaporator freeze-up. This cycling occurs after vehicle cool down - in milder ambients at lower blower speeds, or at higher engine/vehicle speeds. These cycles can be as short as 5 seconds. Even if A/C is not selected, the compressor will operate and can cycle when the air direction control is placed at or between the defrost and floor/defrost symbols. During acceleration from a stop or slow speed, depending on throttle position, the compressor may turn off for a period of time to enhance engine performance. The compressor also turns off for a period of time during wide open throttle. It is normal to feel some change in engine power when the compressor cycles. This normal compressor cycling will not be affected by this repair procedure. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM), and on manual transaxle equipped vehicles built prior to January 28, 1994, replacing the Crankshaft Position Sensor. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181894 > Sep > 94 > PCM Engine Sags, Hesitates, Surge/Occasional Shudder > Page 4119 2. Perform the Relearn - Cam/Crank Alignment Procedure. Using the DRB III, select Engine, select Misc., then select Option # 5 - Relearn - Cam/Crank. NOTE: THE FOLLOWING STEP APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE AND BUILT PRIOR TO JAN. 28, 1994 (MDH 01-28-XX). 3. Remove Crankshaft Position Sensor, outlined on page 8D - 13 in the 1995 Neon Service Manual (Publication No. 81-270-5025). Replace it with P/N 5235377. 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Powertrain Control Module (MTX/ATX) 08-19-01-95 0.4 Hrs. Crank Position Sensor (MTX) 08-15-80-91 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 4124 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > NHTSA94V033000 > Feb > 94 > Recall 94V033000: Moisture Entering PCM Powertrain Control Module: All Technical Service Bulletins Recall 94V033000: Moisture Entering PCM MOISTURE CAN GET INTO THE POWERTRAIN CONTROL MODULE (PCM) CAUSING DRIVEABILITY MALFUNCTIONS, INCLUDING STALLING. SHOULD DRIVE ABILITY MALFUNCTIONS OR STALLING OCCUR WHILE THE VEHICLE IS IN MOTION, A TRAFFIC ACCIDENT MAY OCCUR. THE POWERTRAIN CONTROL MODULES ON THESE VEHICLES WILL BE REPLACED. SYSTEM: TRANSMISSION. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module Powertrain Control Module: All Technical Service Bulletins Recall - Powertrain Control module ATTN: Service Managers Subject: SAFETY RECALL # 614 -- POWERTRAIN CONTROL MODULE (PCM) Involved Vehicles: 1995 Plymouth/Dodge Neon Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Reference: DMAIL message of February 4, 1994, Safety Recall # 614 We are now advising you that the necessary parts, instructions and vehicle lists are in the process of being distributed. Parts are being shipped directly to dealers by UPS and Federal Express (next day air) from the National Parts Depot. Shipments should be completed by Monday, February 14, 1994. Each package will include a powertrain control module (PCM), two PCM mounting screws, a positive battery cable clamp bolt/stud, four rear brake flex hose bracket mounting screws and an emission label (VECI), if required. Instruction sheets are also included. Based on our records, we will ship the proper mix of four different parts packages that are required based on emission/transaxle application. In order to expedite distribution, some dealers may receive more than one parts shipment. VIN LISTINGS: Each dealer will receive the instruction sheets and a list of all involved vehicles by U.S. Priority Mail by February 12, 1994. The list includes a single digit code, located in the third column (column headed "P") to identify which of the four parts packages are required for each VIN listed. Part code: 1=C3906141, 2=C3906142, 3=C3906143 and 4=C3906144. Available parts should be used to fix customer vehicles first, then your stock vehicles. As previously described, you should have picked up any sold vehicles and provided equivalent or better alternate transportation. If for some reason this has not yet been done, dealers are to contact owners immediately by phone and arrange for this service. Upon completion of the repairs, THE VEHICLE MUST BE WASHED, FILLED WITH GAS AND DELIVERED BACK TO THE OWNER. REIMBURSEMENT: The parts package will be invoiced to dealers at $210 each, which can then be marked up and placed on the claim following the normal recall procedures. Use Labor Operation No. 08614182 at 0.5 hours to cover repairs to the vehicle. On Sold Vehicles: Submit a separate claim and use Labor Operation No. 95051950 to cover: - Pick up and delivery of the vehicle - Loaner Expense - Wash - Gas for the actual expense incurred. Parts return is not required and the removed parts must be immediately scrapped. If you are requested to service a vehicle that you did not sell, please contact your Zone Service Office for assistance. PRODUCTION STATUS: Vehicles built after February 1, 1994 (MDH 02-01-XX) will have already been upgraded at the assembly plant. Normal production at Belvedere is expected to resume early next week. ADDITIONAL INFORMATION TO FOLLOW: The normal recall notification instructions will be sent to dealers in the near future. Letters will not be mailed to owners at this time. We will mail to those owners who are not completed by dealer contact in the near future. If you have any questions regarding this action, please contact your Zone Service Office. PARTS PACKAGE C3906141, C3906142, C3906143, C3906144 SAFETY RECALL # 614 Powertrain Control Module (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4134 Models: 1995 Model Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX) Service Requirement Summary: PCM AND BATTERY BOLT/STUD REPLACEMENT: 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 +/- 15 lb-in. (Figure 1). Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4135 3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2). 4. Disconnect PCM 60-way wiring connector. 5. Remove the three PCM mounting screws, disconnect wiring take-out clip and remove PCM with bracket assembly (Figure 3). 6. Route excess 60-way PCM wiring under the front engine compartment wiring harness so that the 60- way wiring forms a downward loop from the PCM (Figure 4). 7. Install the PCM 60-way wiring connector onto the new PCM assembly and torque bolt to 35 lb-in. (New PCM installation bracket positions 60-way connector so that it faces rearward). 8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely. 9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5). Caution: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 614 > Feb > 94 > Recall Powertrain Control module > Page 4136 To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end. 10. Reinstall PDC and lock two release tabs in place. 11. Reinstall positive, then negative battery terminals. VECI LABEL INSPECTION AND INSTALLATION: 12. Inspect the part number of the VECI label mounted on the under-side of the hood and install a new label over the existing one ONLY AS DIRECTED (see illustration). ADDENDUM TO SAFETY RECALL # 614 Models: 1995 Modal Year Plymouth/Dodge Neon (PL) Vehicles Built Through February 1, 1994, (MDH 02-01-XX). Service Requirement Summary: REPLACEMENT OF REAR BRAKE FLEX HOSE MOUNTING BRACKET SCREWS NOTE: THERE ARE SIX SCREWS INCLUDED IN THIS PARTS PACKAGE, ONLY FOUR ARE TO BE USED FOR THE BRAKE FLEX HOSE MOUNTING BRACKET PROCEDURE, AND TWO ARE TO BE USED FOR THE INSTALLATION OF THE PCM MOUNTING BRACKET. 1. Locate the brake flex hose mounting bracket attached to the frame. (See Illustration). 2. Remove and replace the two screws on both sides of the vehicle. Replace them with four of the six screws provided in the parts package. Torque the new screws to 105 +/- 20 in.lbs. (12 +/- 2 N-m). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4137 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4138 Fig. 2 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Powertrain Control Module: Electrical Diagrams Wiring Diagrams For Information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams 5 Volt Supply Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 4159 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation Powertrain Control Module: Description and Operation PCM Operation Fig. 2 Powertrain Control Module (PCM) Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 4162 - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 4163 Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 4164 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Battery Feed Operation BATTERY FEED Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 11 of the powertrain control module (PCM). A 20 amp micro fuse in the PDC protects circuit A14. Internal Controller Failure NAME OF CODE: Internal Controller Failure WHEN MONITORED: With the ignition ON. SET CONDITION: There is an Eraseable Programable Read Only Memory (EPROM) sum check failure at power down. THEORY OF OPERATION: This code indicates the EPROM memory may be corrupt. POSSIBLE CAUSES: - Failed Powertrain Control Module (PCM) PCM Failure EEPROM Write Denied NAME OF CODE: PCM Failure EEPROM Write Denied WHEN MONITORED: With the ignition ON, SBEC tries to write to EEPROM memory. SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus PCM Failure SPI Communications NAME OF CODE: PCM Failure SPI Communications WHEN MONITORED: With the ignition ON. SET CONDITION: Serial communications inside the controller fail eight times during a run cycle. THEORY OF OPERATION: Communications between microprocessors inside the Powertrain Control Module (PCM) are needed to operate the total system. If failure occurs, the solenoids and relays may not actuate properly. POSSIBLE CAUSES: - PCM failure PCM Failure SRI Mile Not Stored NAME OF CODE: PCM Failure SRI Mile Not Stored WHEN MONITORED: With the ignition ON SBEC tries to write service reminder indicator mileage to EEPROM memory. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Operation > Page 4165 SET CONDITION: Unsuccessful attempt to write to EEPROM memory. POSSIBLE CAUSES: - PCM failure - Busy bus 5 Volt Supply Output Too Low NAME OF CODE: 5 Volt supply Output Too Low WHEN MONITORED: With the ignition ON. SET CONDITION: The 5 volt supply to the sensors is below 3.5 volts for 4 seconds. THEORY OF OPERATION: The PCM maintains a 5 volt supply to the MAP sensor, Throttle Position (TP) sensor, and A/C pressure sensor. It is critical that the 5 volt supply stays between 4.8 and 5.1 volts as this input has a direct effect on sensor output voltages. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut-Down (ASD) relay and fuel pump relay. The A14 circuit also splices to the data link connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4168 Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) PCM 60 Way Connector Checks Powertrain Control Module 60-Way Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4169 Check the powertrain control module (PCM) 60-way connector for: - Spread terminals - Stretched or pulled out wires - Moisture or corrosion - Under-tightened or over-tightened 60 way connector Tighten the PCM connector to 4 Nm (35 in lb) torque. When checking terminal pinouts, refer to the Powertrain Control Module 60-Way Connector Diagram for circuit wire colors and cavity numbers. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 4170 Powertrain Control Module: Service and Repair Fig. 21 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 21). REMOVAL 1. Disconnect negative cable from battery 2. Remove screws attaching PCM to body 3. Lift PCM up. Disconnect PCM 60-way connector. 4. Remove PCM. INSTALLATION 1. Attach 60-way connector to PCM. Tighten 60-way connector screw to 4.5 Nm (40 in lb) torque. 2. Install PCM. Tighten mounting screws to 9 Nm (80 in lb) torque. 3. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 4195 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 4196 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 4197 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 4198 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 4204 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 4205 Absolute Pressure Sensor: Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4209 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 4212 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4221 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4222 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 4244 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 4245 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 4246 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 4249 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 4250 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 4251 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MAP/Coolant Sensor Torque Revisions NUMBER: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Map & Coolant Sensor Torque Corrected Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 4256 8D - 17 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MAP/Coolant Sensor Torque Revisions > Page 4257 Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins MAP/Coolant Sensor - Torque Revised NO: 08-27-94 GROUP: Electrical DATE: Jun. 17, 1994 SUBJECT: Service Manual Revision- Map & Coolant Sensor Torque MODELS: 95 (PL) Neon This Technical Service Bulletin references revised service manual pages. MANUAL PUBLICATION PAGE CHANGE 1995 Neon 81-270-5025 8D - 17 Map & Coolant Sensor Torque Corrected POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4258 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor Torque = 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4259 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Engine Coolant Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description NAME OF CODE: Closed Loop Temp Not Reached WHEN MONITORED: After engine is started, for ten minutes. SET CONDITION: The engine temperature does not go above 60° by 10 minutes after the engine is started. THEORY OF OPERATION: The engine coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. As coolant temperature increases, resistance decreases and the voltage will be low. This allows the sensor to provide an analog voltage signal (0 to 5-volt) to Powertrain Control Module (PCM) cavity 28. To make the sensor more accurate at cold and hot temperatures, the 5-volt signal passes through a 10,000 ohm resistor or through a 1,000 ohm resistor connected in parallel with the 10,000 ohm resistor, which has a calculated resistance value of 909 ohms. If the engine is cold (below 125° F), the 5-volt supply to the engine coolant temperature sensor is fed only through the 10,000 ohm resistor inside the PCM. If the engine is warm (above 125° F), the 5-volt supply to the engine coolant temperature sensor is fed through both resistors. POSSIBLE CAUSES: - Thermostat failure - ECT failure - Faulty connections - Extremely cold ambient temperature - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Engine Coolant Temperature Sensor Description > Page 4281 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Operation Fig. 18 Engine Coolant Temperature Sensor PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the rear of the cylinder head, next to the camshaft position sensor (Fig. 10). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine coolant temperature gauge in the instrument cluster on circuit G2O. Refer to Section Instrument Cluster for coolant temperature gauge circuit description. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 28 of the PCM connector, and cavity 1 of the sensor connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Component Testing Fig. 26 Engine Coolant Temperature Sensor Location 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 26). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt- ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Helpful Information The engine coolant temperature sensor is case- grounded, which provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Battery temperature sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4284 ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 4285 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 11 Engine Coolant Temperature Sensor NOTE: The combination engine coolant sensor is located at the rear of the cylinder head next to the camshaft position sensor (Fig. 11). REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. See Cooling System. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. Tighten sensor to 7 Nm (60 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. See Cooling System. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4289 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 4311 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 4312 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 4313 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 4314 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 4315 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 4318 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 4319 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor Torque ....................................................................................................................................................... 10 Nm (90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 4323 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Intake Air Temperature Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 Intake Air Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor-PCM Input Fig. 4 Intake Air Temperature Sensor And MAP Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the intake air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse width and spark advance. The IAT sensor threads into the intake manifold (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 4345 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation Fig. 16 Intake Air Temperature Sensor And MAP Sensor PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 6 of the PCM, and cavity 1 of the sensor connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 4346 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High NAME OF CODE: Intake Air Temp Sensor Voltage High WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes above 4.9 volts. THEORY OF OPERATION: The Intake Air Temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor-PCM Input > Page 4347 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low NAME OF CODE: Intake Air Temp Sensor Voltage Low WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The intake air sensor circuit voltage at Powertrain Control Module (PCM) cavity 6 goes below 0.157 volt. THEORY OF OPERATION: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 6. The PCM uses this signal to compensate for changes in air density due to temperature. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector wires/terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 4350 Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 28 Intake Air Temperature Sensor 1. With the key off, disconnect wire harness connector from the intake air temperature sensor (Fig. 28). 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 6 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. NOTE: Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 4351 Intake Air Temperature Sensor: Service and Repair Fig. 10 Intake Air Temperature Sensor And MAP Sensor NOTE: The intake air temperature sensor threads into the intake manifold plenum (Fig. 10). REMOVAL 1. Remove engine cover. 2. Disconnect electrical connector from sensor. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Install engine cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 4355 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 4375 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 4378 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 4383 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4384 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Manifold Pressure/Vacuum Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 Manifold Absolute Pressure Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Operation Fig. 4 Intake Air Temperature Sensor And MAP Sensor The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately - As vacuum decreases, MAP sensor voltage increases proportionately Key ON At key ON -- during cranking, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. Engine Running While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP sensor mounts to the intake manifold (Fig. 4). CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 29 of the PCM, and cavity 3 of the MAP connector. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 2 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 4406 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: The MAP sensor is a semiconductor type sensor. This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Signal circuit open - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM MAP Sensor Voltage Too Low NAME OF CODE: MAP Sensor Voltage Too Low WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The Manifold Absolute Pressure (MAP) sensor signal voltage is below 1.2 volts at start, or below 0.2 volt for 1.76 seconds with engine running. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - Failed PCM No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition ON and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 29. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Operation > Page 4407 high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 43; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM No 5 Volts to MAP Sensor NAME OF CODE: No 5 Volts to MAP Sensor WHEN MONITORED: With the ignition OFF. SET CONDITION: The MAP sensor signal voltage goes below 1.96 volts. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5 volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. - The MAP receives a 5 volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - MAP sensor failure TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 4410 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Refer to Group 14 for Manifold Absolute Pressure (MAP) sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 4411 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 17 Intake Air Temperature Sensor And MAP Sensor NOTE: The MAP sensor attaches to the intake manifold plenum (Fig. 17). REMOVAL 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions Oxygen Sensor: Technical Service Bulletins Engine Controls/Electrical - Manual Revisions NUMBER: 08-32-94 GROUP: Electrical DATE: Jul. 15, 1994 REVISIONS ARE HIGHLIGHTED WITH ASTERISKS Models: 1995 Neon Service Manual Supplement - Publication No. 81-270-5025A DESCRIPTION OF CHANGES O2 Sensor K42 Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 4416 8W-30-16 Eliminate Alternate Cavity 15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 4417 8W-80-8 Eliminate Alternate Cavity 2 On Connector C142 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls/Electrical - Manual Revisions > Page 4418 8W-80-15 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4419 Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 4422 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 4423 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 Oxygen Sensor: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 Oxygen Sensors Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4443 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description Oxygen Sensor: Description and Operation Oxygen Sensor Description Downstream Oxygen Sensor Fig. 13 Downstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Upstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4446 Fig. 12 Upstream Heated Oxygen Sensor HEATED OXYGEN SENSORS-PCM INPUT As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor - One downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. PURPOSE The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. OPERATION The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. - When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Heating Element The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. - Also, it allows the system to remain in closed loop operation during periods of extended idle. Closed Loop Operation In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. Open Loop Operation In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). CIRCUIT OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4447 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure NAME OF CODE: Downstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the PCM powers up the sensor heater. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Downstream O2 Sensor Shorted to Ground NAME OF CODE: Downstream O2S Shorted To Ground WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: The downstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage NAME OF CODE: Downstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The downstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the Powertrain Control Module (PCM) how well the catalytic converter is oxidizing HC and CO components Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4448 and reducing NOx components in the engine exhaust gas. Variations in the signals from this O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream O2 sensor indicates a deficiency of oxygen when the upstream O2 sensor detects an abundance of oxygen and vice versa. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Downstream O2 Sensor Slow Response NAME OF CODE: Downstream O2 Sensor Slow Response WHEN MONITORED: With the vehicle engine temperature greater than 170° F and engine speed over 1,600 rpm. Rich response test is conducted when at WOT, with the front O2 sensor indicating a rich F/A condition. Lean response test is conducted when at closed throttle, in decel fuel shut-off (except SOHC automatic transmission vehicles), and with the front O2 sensor indicating a lean F/A condition. SET CONDITION: The rich response test will fail if the downstream O2 sensor voltage is less than 0.60 volts within 5 seconds of meeting the test conditions. The lean response test will fail if the downstream voltage is greater than 0.29 volts within 5 seconds of meeting the test conditions. The trouble code will be set if either (or both) tests fail three times per trip. Once the rich and lean response test each pass once, the testing is complete that trip. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Exhaust leak - Fuel contamination - Electrical wiring connectors - Engine mechanical Downstream O2 Sensor Stays at Center NAME OF CODE: Downstream O2 Sensor Stays at Center WHEN MONITORED: With the vehicle engine running for over 2 minutes, temperature greater than 170° F, in closed loop. SET CONDITION: With oxygen sensor voltage staying between 0.39 volts and 0.52 volts during the trip, the PCM pulls the sensor voltage to 5.0 volts for 30 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300 - 350° C (572 - 662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). POSSIBLE CAUSES: - Sensor output wire open - Electrical wiring connectors - Open ground circuit - PCM failure - Oxygen sensor failure O2S Stays Above Center (Rich) NAME OF CODE: O2S Stays Above Center (Rich) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4449 WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays between 0.5 and 1.2 volts without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - High fuel pressure - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem O2S Stays Below Center (Lean) NAME OF CODE: O2S Stays Below Center (Lean) WHEN MONITORED: With the engine running in closed loop and the coolant temperature above 170°F. SET CONDITION: The oxygen sensor signal voltage stays below 0.5 without toggling for at least 8 minutes. THEORY OF OPERATION: The oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reation within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When the oxygen content is low (rich mixture) the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture) the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Low fuel pressure - Vacuum Leak - Other engine sensor calibrations - Ignition system failure - O2 sensor failure - Mechanical engine problem Upstream O2 Sensor Heater Failure NAME OF CODE: Upstream O2S Heater Failure WHEN MONITORED: With the ignition key OFF, after the engine cools down. SET CONDITION: No sensor output signal is received when the Powertrain Control Module (PCM) powers up the sensor heater. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4450 the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. POSSIBLE CAUSES: - Open heater element circuit - O2 sensor failure Upstream O2 Sensor Shorted to Ground NAME OF CODE: Upstream O2 Sensor Voltage Shorted to Ground WHEN MONITORED: With the ignition key off, after the engine cools down. SET CONDITION: The upstream oxygen sensor signal voltage is below 0.156 volts prior to O2 sensor heater test. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - PCM failure - Connector terminals - Connector wires Upstream O2 Sensor Shorted to Voltage NAME OF CODE: Upstream O2S Shorted To Voltage WHEN MONITORED: With the ignition key ON. SET CONDITION: The upstream oxygen sensor signal voltage is above 1.2 volts. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The Powertrain Control Module (PCM) receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure Upstream O2 Sensor Slow Response NAME OF CODE: Upstream O2S Response WHEN MONITORED: With the engine running for more than 3 minutes, engine temperature greater than 170° F, after reaching a vehicle speed of 24 MPH, at idle with Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor Description > Page 4451 the transmission in drive (auto) or in neutral (manual). SET CONDITION: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. THEORY OF OPERATION: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300-350° C (572-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. POSSIBLE CAUSES: - Exhaust leak - Fuel contamination Upstream O2 Sensor Stays at Center NAME OF CODE: Upstream O2S Stays at Center WHEN MONITORED: With the engine running for more than 2 minutes and engine temperature greater than 170° F. SET CONDITION: The upstream oxygen sensor signal voltage is 0.5 volts for 1.5 minutes. THEORY OF OPERATION: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. POSSIBLE CAUSES: - Sensor output wire open - O2 sensor failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 4452 Oxygen Sensor: Testing and Inspection NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 4455 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 4456 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 4465 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 4471 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4476 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4477 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4478 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 4479 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4484 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4485 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4486 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4487 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 4493 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 4494 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 4495 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 4496 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4501 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4502 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4503 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 4504 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4507 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 4508 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 4530 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 4539 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 4545 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4548 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4549 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 4571 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 4572 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 4575 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 4576 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 4577 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4599 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 4610 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 4616 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 4617 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Vehicle Speed Sensor: Electrical Diagrams Complete System Diagram For wiring Diagrams, refer to Powertrain Management/Diagrams/Electrical. See: Diagrams/Electrical Diagrams Vehicle Speed Sensor Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 180°F. SET CONDITION: No signal from the vehicle speed sensor (TCM) is present for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor is a hall effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. - The PCM supplies 8 volts from cavity 44 to power up the sensor. - Sensor ground is supplied by PCM cavity 51. - The PCM also supplies a 5.0 volt pull up voltage to the sensor from cavity 5. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion damaged - Open 8 volt supply circuit - Open sensor circuit ground - Failed speed sensor - PCM failure - Connector Terminals/Wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal > Page 4639 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 4640 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 4641 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 7 Nm (60 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 4650 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 4656 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4659 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4660 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 4682 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 4683 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 4686 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 4687 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 4688 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4710 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 4721 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative Vehicle Speed Sensor: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 4727 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 4728 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Vehicle Speed Sensor: Electrical Diagrams Complete System Diagram For wiring Diagrams, refer to Powertrain Management/Diagrams/Electrical. See: Diagrams/Electrical Diagrams Vehicle Speed Sensor Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 180°F. SET CONDITION: No signal from the vehicle speed sensor (TCM) is present for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor is a hall effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. - The PCM supplies 8 volts from cavity 44 to power up the sensor. - Sensor ground is supplied by PCM cavity 51. - The PCM also supplies a 5.0 volt pull up voltage to the sensor from cavity 5. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion damaged - Open 8 volt supply circuit - Open sensor circuit ground - Failed speed sensor - PCM failure - Connector Terminals/Wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal > Page 4750 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 4751 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 4752 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 7 Nm (60 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications Voltage Signal: Specifications The PCM tries to maintain system voltage between 12.9 volts and 15.0 volts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications > Page 4756 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions Voltage Signal: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Voltage Signal: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Voltage Signal: Electrical Diagrams Charging System Circuit Battery Temperature Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation Voltage Signal: Description and Operation Description of Operation THEORY OF OPERATION: The PCM monitors battery voltage input to determine fuel injector pulse width and generator field control voltage. Injector Pulse Width If voltage is low the PCM will increase pulse width (the period of time that the injector is energized). Generator Field Voltage The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at the PCM. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. - If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 4778 Voltage Signal: Description and Operation Battery Temperature Sensor PURPOSE The PCM uses the temperature of the battery area to control the charge rate. OPERATION The signal is used to regulate the system voltage. The system voltage is higher at cold temperatures and is gradually reduced as temperature is increased. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 4779 Voltage Signal: Description and Operation Charging System Voltage Too High NAME OF CODE: Charging System Voltage Too High WHEN MONITORED: With the ignition key ON and the engine running above 1500 RPM for 1 minute. SET CONDITION: This trouble code sets when the Powertrain Control Module (PCM) tries to regulate the generator field and there are no detected field problems but, the sensed battery voltage continues to increase. THEORY OF OPERATION: The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at PCM pin # 11. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. POSSIBLE CAUSES: - Generator internal short - Generator field driver short to ground - The sensed battery voltage is less than actual - Powertrain control module failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 4780 Voltage Signal: Description and Operation Charging System Voltage Too Low NAME OF CODE: Charging System Voltage Too Low WHEN MONITORED: With the ignition key ON and the engine running above 1500 RPM for 1 minute. SET CONDITION: With no other charging system codes set. The battery sensed voltage is below the charging goal. The PCM senses the battery voltage, turns off the field driver and senses the battery voltage again. If the voltages are the same the code is set. THEORY OF OPERATION: The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at PCM pin # 11. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. POSSIBLE CAUSES: - Defects in generator drive belt or adjustment - High resistance between battery B(+) and generator B(+) - High resistance between battery B(-) and generator B(-) - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 4781 Voltage Signal: Description and Operation Generator Field Not Switching Properly NAME OF CODE: Generator Field Not Switching Properly WHEN MONITORED: With the ignition key ON and the engine running. SET CONDITION: This trouble code sets when the Powertrain Control Module (PCM) tries to regulate the generator field with no result during monitoring. THEORY OF OPERATION: The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at PCM pin #11. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage, the PCM will supply more ground to the field circuit. If the sensed voltage is more than the control voltage, the PCM will supply less ground to the field circuit. POSSIBLE CAUSES: - Field driver circuit open or shorted - Generator internal open or short - Powertrain control module failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > System Information > Description and Operation > Low Secondary Air Flow -- Manual Transmission Only Secondary Air Supply: Description and Operation Low Secondary Air Flow -- Manual Transmission Only NAME OF CODE: Low Secondary Air Flow WHEN MONITORED: After engine start-up at idle. The secondary air monitor feature performs a functional and flow rate test of the secondary air system by monitoring the response of the dual O2 system with the air system active and inactive. SET CONDITION: The PCM does not see a calibrated amount of change in the dual O2 system for a calibrated amount of tests. THEORY OF OPERATION: The secondary air solenoid allows the air aspirator system to be turned ON for a period of time after start up. This system contains an air shut-off solenoid in line between the air cleaner and the aspirator valve. The air shut-off valve is a vacuum actuated diaphragm valve with an electric solenoid to control vacuum supplied to the diaphragm valve. An aspirator valve utilizes exhaust pressure pulsation to draw air into the exhaust system reducing carbon monoxide and hydrocarbon emissions. The system draws fresh air through the air cleaner and passes it through either a steel reed valve or a loaded one-way rubber diaphragm. POSSIBLE CAUSES: - Aspirator valve failure - Leaking exhaust system - Solenoid failure - Broken or collapsed hoses and tubes Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > System Information > Description and Operation > Low Secondary Air Flow -- Manual Transmission Only > Page 4787 Secondary Air Supply: Description and Operation Secondary Air Solenoid -- Manual Transmissions Only NAME OF CODE: Secondary Air Solenoid WHEN MONITORED: After engine start up at idle and slightly off idle. The secondary air solenoid is monitored by the PCM and works in conjunction with the aspirator valve, which, at higher engine speeds, remains closed. SET CONDITION: The secondary air solenoid circuit is not in the expected state when requested by the PCM. THEORY OF OPERATION: The secondary air solenoid allows the air aspirator system to be turned ON or off at specific operational modes. This system contains an air shut off solenoid in line between the air cleaner and the aspirator valve. The air shut-off valve is a vacuum actuated diaphragm valve with an electric solenoid to control vacuum supplied to the diaphragm valve. An aspirator valve utilizes exhaust pressure pulsation to draw air into the exhaust system reducing carbon monoxide and to a lesser degree, hydrocarbon emissions. The system draws fresh air through the air cleaner and passes it through either a steel reed valve or a loaded one-way rubber diaphragm. POSSIBLE CAUSES: - Open/short secondary air solenoid circuit - Open fused ignition switch output circuit to splice - Secondary air solenoid - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Solenoid Coil Resistance @ 20°C (68°F) ......................................................................................................................................................... 25 - 35 ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 4796 Canister Purge Solenoid: Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions Canister Purge Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 Canister Purge Solenoid: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Evap Solenoid Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid Canister Purge Solenoid: Description and Operation Duty Cycle EVAP/Purge Solenoid Fig. 3 Duty Cycle EVAP Purge Solenoid PURPOSE The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. When purging, the PCM energizes and de-energizes the solenoid approximately 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. - Pulse width is the amount of time the solenoid energizes. The solenoid attaches to a bracket which is attached to the front engine mount (Fig. 3). CIRCUIT OPERATION Circuit F18 supplies battery voltage to the duty cycle EVAP/Purge solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K52. Circuit F18 connects to a bus bar in the fuse block fed by circuit A21. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. Circuit F18 connects to cavity 54 of the PCM, and cavity 1 of the solenoid connector. Circuit K52 connects to cavity 16 of the PCM, and cavity 2 of the solenoid connector. NOTE: The solenoid will not operate properly unless it is installed with the electrical connector at the top. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid > Page 4818 Canister Purge Solenoid: Description and Operation EVAP Purge Solenoid Circuit Failure Code NAME OF CODE: Evaporative Purge Solenoid Circuit WHEN MONITORED: With the ignition key ON and the engine running. SET CONDITION: After the arming conditions are satisfied: not powering down, not already in limp-in, time since the last solenoid activation>72 micro seconds. The PCM will set a trouble code if the actual state of the solenoid does not match the intended state. THEORY OF OPERATION: The EVAP purge solenoid is mounted on the right side shock tower. Its purpose is to regulate, by means of a duty cycle, the flow of vapors from the EVAP canister to the throttle body. The PCM controls the time the solenoid is ON during a duty cycle. During off idle operations (higher flows), higher percentages of duty cycle are used. At idle (lower flow), lower percentages of duty cycle are used. POSSIBLE CAUSES: - Open or shorted control circuit - Open fused ignition switch output circuit - Open or shorted solenoid control coil - PCM failure - Connector wires or terminals Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection Canister Purge Solenoid: Testing and Inspection EVAP Purge Solenoid Inspection EVAPORATIVE EMISSION PURGE SOLENOID INSPECTION NOTE: When disconnecting the vacuum hose, place an identification mark on it for proper re-connection. 1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve. Battery Voltage / Normal Condition. Applied ....................................................................................... .......................................................................................................... Vacuum Leaks Not Applied ...... .............................................................................................................................................................. ............. Vacuum Maintained 5. Measure the resistance between the terminals of the solenoid valve. - Standard value: 25-35 ohms [at 20°C (68°F)] Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection > Page 4821 Canister Purge Solenoid: Testing and Inspection Helpful Information Circuit F18 splices to feed the ABS control module, PCM, EET solenoid and the TCC solenoid. The F18 circuit also connects to a bus bar in the Power Distribution Center (PDC) that supplies voltage to the coil side of radiator fan relay, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 amp fuse in the PDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Page 4822 Canister Purge Solenoid: Service and Repair Fig. 13 Duty Cycle EVAP Purge Solenoid NOTE: The solenoid attaches to a bracket near the front engine mount (Fig. 13). The solenoid will not operate unless it is installed correctly REMOVAL 1. Disconnect electrical connector from solenoid. 2. Disconnect vacuum tubes from solenoid. 3. Remove solenoid from bracket. NOTE: The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. INSTALLATION 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Fig.1 EVAP Canister Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 4826 Evaporative Emission Control Canister: Description and Operation Fig. 2 EVAP Canister All vehicles use a sealed, maintenance free, evaporative (EVAP) canister. Fuel tank pressure vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The PCM purges the canister through the duty cycle EVAP purge solenoid. - The PCM purges the canister at predetermined intervals and engine conditions. The canister mounts to a bracket behind the front fascia on the passengers side of the vehicle (Fig. 2). The vacuum and vapor tube connect to the top of the canister. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4835 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4836 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4837 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4838 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4839 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4840 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4841 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4847 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4848 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4849 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4850 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4851 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4852 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 4853 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation Electric EGR Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Page 4858 Electric EGR Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions EGR Control Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 EGR Control Solenoid: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 EGR Solenoid Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Electronic EGR Transducer (EET) Solenoid Operation EGR Control Solenoid: Description and Operation Electronic EGR Transducer (EET) Solenoid Operation Fig. 2 Electronic EGR Transducer (EET) ELECTRONIC EGR TRANSDUCER (EET) SOLENOID Circuit F18 supplies battery voltage to the EET solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K35. Circuit F18 connects to a bus bar in the fuse block fed by circuit A21. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. Circuit F18 connects to cavity 54 of the PCM, and splices to the solenoid connector. Circuit K35 connects to cavity 39 of the PCM, and cavity 2 of the solenoid connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Electronic EGR Transducer (EET) Solenoid Operation > Page 4883 EGR Control Solenoid: Description and Operation EGR Solenoid Circuit NAME OF CODE: EGR Solenoid Circuit WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: The EGR solenoid control circuit is not in the expected state when requested to operate by the Powertrain Control Module (PCM). THEORY OF OPERATION: The EGR solenoid is actuated by the PCM when the engine is at normal operating temperature. Throttle position sensor shows other than idle or wide open throttle (WOT) and manifold absolute pressure (MAP) is in mid operating range. The PCM looks for a current spike when actuating the solenoid. If the spike is not present the PCM sets a trouble code. POSSIBLE CAUSES: - Open or shorted control circuit - Open fused ignition switch output circuit - Open or shorted solenoid control coil - Powertrain control module failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Page 4884 EGR Control Solenoid: Testing and Inspection Circuit F18 splices to feed the ABS control module, PCM, duty cycle EVAP/Purge solenoid and the EMCC solenoid. The F18 circuit also connects to a bus bar in the PDC that supplies voltage to the coil side of radiator fan relay, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 amp fuse in the PDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Page 4885 EGR Control Solenoid: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair Fig. 1 EGR System Fig. 3 EGR Tube Stud Bolts NOTE: The EGR tube attaches to the intake manifold plenum below the throttle body and EGR valve (Fig. 1). REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 3). 2. Remove EGR tube to EGR valve screws. 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: The rubber grommet that seals the EGR tube to intake manifold connection is reusable. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Fig. 5 Oil Separator This engine PCV system contains an oil separator (Fig. 5). The oil separator attaches to the engine, behind the intake manifold. Crankcase vapors enter the bottom of the separator. Oil collected in the separator drains back into the crankcase from an outlet in the bottom of the separator. Fig. 6 PCV Valve And Oil Separator (Intake Manifold Removed) The PCV valve connects to the separator and to intake manifold vacuum (Fig. 6). Make-up air is supplied to the separator by a hose connected to the air cleaner air tube. Intake manifold vacuum removes crankcase vapors and piston blow-by from the separator. Emissions pass through the PCV valve into the intake manifold plenum. The vapors become part of the calibrated air-fuel mixture, are burned and then expelled with the exhaust gases. The air cleaner supplies make up air when the engine does not have enough vapor or blow-by gases. PCV VALVE The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 7 Engine Off Or Engine Backfire - No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 4892 flowing through the valve (Fig. 7). Fig. 8 High Intake Manifold Vacuum - Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve (Fig. 8). In this position there is minimal vapor flow through the valve. Fig. 9 Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 4893 Positive Crankcase Ventilation: Testing and Inspection PCV SYSTEM INSPECTION WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. 1. With engine idling, remove the vapor hose from the PCV valve. - If the valve is not plugged, a hissing noise will be heard as air passes through the valve. - A strong vacuum should also be felt when a finger is placed over the valve inlet. 2. Install hose on PCV valve. 3. Remove the make-up air hose from the air plenum at the rear of the engine. 4. Hold a piece of stiff paper (parts tag) loosely over the end of the make-up air hose. - After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. - If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose. 5. Turn the engine off. 6. Remove the PCV valve from intake manifold. - The valve should rattle when shaken. NOTE: If THE PCV VALVE does not operate as described in the preceding tests, replace the PCV valve and retest the system. DO NOT attempt to clean the old PCV valve. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 4894 Positive Crankcase Ventilation: Service and Repair 1. Remove intake manifold. 2. Remove PCV valve hose from oil separator. CAUTION: Constant tension hose clamps are used on the separator hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as Special Clamp Tool (number 6094 OR equivalent). CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. 3. Remove hose clamps and 2 hoses from bottom of separator. 4. Remove 2 bolts holding separator to block. 5. Reverse the removal procedures to install an oil separator. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4903 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest: > 141294 > Jun > 94 > Accelerator Pedal - Vibration While Driving Accelerator Pedal: Customer Interest Accelerator Pedal - Vibration While Driving NO: 14-12-94 GROUP: Fuel DATE: Jun. 6, 1994 SUBJECT: Accelerator Pedal Vibration MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO THE FOLLOWING VEHICLES: AUTOMATIC TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-11-XX. MANUAL TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-18-XX. SYMPTOM/CONDITION: Automatic and Manual Transmission - Vibration felt through the accelerator pedal at 3000 to 3500 RPM's while driving. Manual Transmission - Vibration felt through the accelerator pedal at idle or low engine RPM's while driving. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4669467 Throttle Cable Assembly - Man. Trans. 1 4669468 Throttle Cable Assembly - Auto. Trans. REPAIR PROCEDURE: This bulletin involves removal, replacement and rerouting of the throttle cable assembly. 1. Following the procedures outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-14 and 14-15, replace the throttle cable assembly with the appropriate new cable listed in the parts section of this bulletin. NOTE: ROUTE THE NEW THROTTLE CABLE ASSEMBLY INBOARD OF THE HEATER HOSES, UNDERNEATH THE AIR CLEANER FRESH AIR DUCT AND OVER THE TOP OF THE SPEED CONTROL CABLE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-80-25-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 141294 > Jun > 94 > Accelerator Pedal Vibration While Driving Accelerator Pedal: All Technical Service Bulletins Accelerator Pedal - Vibration While Driving NO: 14-12-94 GROUP: Fuel DATE: Jun. 6, 1994 SUBJECT: Accelerator Pedal Vibration MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO THE FOLLOWING VEHICLES: AUTOMATIC TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-11-XX. MANUAL TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-18-XX. SYMPTOM/CONDITION: Automatic and Manual Transmission - Vibration felt through the accelerator pedal at 3000 to 3500 RPM's while driving. Manual Transmission - Vibration felt through the accelerator pedal at idle or low engine RPM's while driving. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4669467 Throttle Cable Assembly - Man. Trans. 1 4669468 Throttle Cable Assembly - Auto. Trans. REPAIR PROCEDURE: This bulletin involves removal, replacement and rerouting of the throttle cable assembly. 1. Following the procedures outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-14 and 14-15, replace the throttle cable assembly with the appropriate new cable listed in the parts section of this bulletin. NOTE: ROUTE THE NEW THROTTLE CABLE ASSEMBLY INBOARD OF THE HEATER HOSES, UNDERNEATH THE AIR CLEANER FRESH AIR DUCT AND OVER THE TOP OF THE SPEED CONTROL CABLE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-80-25-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4925 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4926 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4927 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4932 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4938 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4939 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4940 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accelerator Pedal: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4945 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Page 4946 Accelerator Pedal: Service and Repair Fig. 1 Accelerator Pedal And Throttle Cable -- Front View Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View CAUTION: When servicing the accelerator pedal or throttle cable, do not damage or kink the control cable core wire. REMOVAL 1. Remove the throttle cable from the throttle body cam as described in Throttle Cable of this section. 2. Hold up the accelerator pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 1 and Fig. 2). 3. Working from the engine compartment, remove nuts from accelerator pedal assembly studs (Fig. 1). Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in lb) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 3. Hold the throttle body lever in the wide open position and install the throttle cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 1 Air Cleaner AIR CLEANER Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. The air cleaner attaches to a bracket on the rear of the cylinder head (Fig. 1). An ambient air duct supplies underhood air for the engine. FILTER ELEMENT REPLACEMENT 1. Unfasten clasps of front of air cleaner lid. Lift lid off of air cleaner housing. 2. Remove clean air duct from throttle body. 3. Remove make-up air hose. Fig. 2 Air Cleaner Housing And Element 4. Remove filter element (Fig. 2). 5. If necessary, clean the inside of the air cleaner housing. 6. Install new filter element. 7. Place lid over air cleaner housing. Snap clasps over the air cleaner lid. 8. Install clean air duct to throttle body CAUTION: DO NOT Over Torque Air Cleaner Housing Cover Clamps. 9. Tighten air cleaner cover clamps to (15-25 in lb). 10. Install make-up air hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 141394 > Jul > 94 > Idle Air Control Motor - Whistle Noise Auxiliary Air Valve (Idle Speed): Customer Interest Idle Air Control Motor - Whistle Noise NO: 14-13-94 GROUP: Fuel DATE: Jul. 1, 1994 SUBJECT: Idle Air Control Motor Whistle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 1, 1994 (MDH 06-01-XX). SYMPTOM/CONDITION: A high-pitched whistling noise from the engine compartment is noticeable at idle. The noise may be more prevalent when the engine is idling in gear and under a load; such as air conditioning, or headlamps on. No whistling noise can be heard while cruising. DIAGNOSIS: Place the gear selector in park or neutral, set the parking brake and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Listen for the whistle noise. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. PARTS REQUIRED: 1 4796503 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Following the procedures outlined in the 1995 Neon Service Manual, Publication No. 81-270-5025 pages 14-45 and 14-46, replace the idle air control motor with new motor P/N 4796503. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-30-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 141394 > Jul > 94 > Idle Air Control Motor - Whistle Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Idle Air Control Motor - Whistle Noise NO: 14-13-94 GROUP: Fuel DATE: Jul. 1, 1994 SUBJECT: Idle Air Control Motor Whistle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 1, 1994 (MDH 06-01-XX). SYMPTOM/CONDITION: A high-pitched whistling noise from the engine compartment is noticeable at idle. The noise may be more prevalent when the engine is idling in gear and under a load; such as air conditioning, or headlamps on. No whistling noise can be heard while cruising. DIAGNOSIS: Place the gear selector in park or neutral, set the parking brake and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Listen for the whistle noise. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. PARTS REQUIRED: 1 4796503 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Following the procedures outlined in the 1995 Neon Service Manual, Publication No. 81-270-5025 pages 14-45 and 14-46, replace the idle air control motor with new motor P/N 4796503. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-30-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fig. 4 Pressure Vacuum Filler Cap WARNING: Remove fuel filler tube cap to relieve tank pressure before removing or repairing fuel system components. PURPOSE A pressure-vacuum relief cap seals the fuel tank (Fig. 4). The loss of any fuel or vapor out of the filler tube neck is prevented by the use of a safety filler cap. OPERATION Tightening the cap on the fuel filler tube forms a seal between them. The relief valves in the cap are a safety feature. They prevent possible excessive pressure or vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the vent lines. The seal between the cap and filler tube breaks when the cap is removed. Breaking the seal relieves fuel tank pressure. Pressure Release The cap releases only under significant pressure 10.9 to 13.45 kPa (1.58 to 1.95 psi). Vacuum Release The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). Replacement If the filler cap needs replacement, only use an original equipment or equivalent unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4974 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Injector resistance should be between 10 ohms and 16 ohms. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Fuel Injector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 Fuel Injector: Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Injector Driver Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description Fuel Injector: Description and Operation Fuel Injectors Description FUEL INJECTORS Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut-Down ( ASD) relay connects circuit A14 and circuit A142. A 20 amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 18 of the PCM connector. Circuit A142 supplies voltage for the fuel injectors. The PCM controls the ground circuit of each injector, as follows: ^ Circuit K11 is the ground circuit for Injector # 1. Circuit K11 connects to cavity 4 of the PCM. ^ Circuit K12 is the ground circuit for Injector # 2. Circuit K12 connects to cavity 23 of the PCM. ^ Circuit K13 is the ground circuit for Injector # 3. Circuit K13 connects to cavity 3 of the PCM. ^ Circuit K14 is the ground circuit for Injector # 4. Circuit K14 connects to cavity 24 of the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description > Page 5000 Fuel Injector: Description and Operation Injector Control Circuit NAME OF CODE: Injector Control Circuit WHEN MONITORED: With battery voltage greater than 12 volts, the auto shutdown (ASD) relay energized, injector pulse width less than 10 milliseconds, and engine speed less than 3000 RPM. SET CONDITION: This trouble code takes 0.64 to 10.0 seconds to set when no inductive kick is sensed 0.18 milliseconds after injector turns off, and with no other injectors on. THEORY OF OPERATION: Fuel injectors are high-impedance solenoids controlled by the Powertrain Control Module (PCM). Battery voltage is supplied by the ASD relay. The injector ON time (pulse width) is controlled by the amount of time the PCM grounds the injector control circuit. By varying this time, more or less fuel is allowed to flow through the injector. POSSIBLE CAUSES: - Open or shorted injector driver circuit - Open injector - Open ASD supply at injector - Failed driver in PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information Fuel Injector: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, Automatic Shut-Down (ASD) relay, generator, and the upstream and downstream heated oxygen sensors. The Powertrain Control Module (PCM) controls the ground circuit for each of the components powered by circuit A142. The injectors operate in sequence. Refer to Group 14 for system operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 5003 Fuel Injector: Testing and Inspection Resistance Test Related Images Check resistance between the injector terminals. Resistance should be between 10 and 16 ohms. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 5004 Fuel Injector Diagnosis Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 5005 Fuel Injector: Service and Repair Fig. 6 Fuel Rail And Injectors REMOVAL 1. Disconnect negative cable from battery 2. Release fuel system pressure. Refer to procedure. 3. Disconnect fuel supply tube from rail. 4. Disconnect electrical connectors from fuel injectors (Fig. 6). 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. Fig. 7 Fuel Injector Retainer 7. Remove fuel injector retainer (Fig. 7). 8. Pull injector out of fuel rail. Replace fuel injector 0-rings. INSTALLATION 1. Apply a light coating of clean engine oil to the upper 0-ring. 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector. 5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 19.5 Nm -25.5 Nm (170 to 230 in lb). 6. Attach electrical connectors to fuel injectors. 7. Connect fuel supply tube to fuel rail. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair Fig. 20 Plastic Quick-Connect Fittings NOTE: Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable 0-ring seals (Fig. 20). CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fitting or fuel tubes. Replace the complete fuel tube/quick-connect fining assembly. OPERATION The quick-connect fitting consists of the 0-rings, retainer and casing (Fig. 20). When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube. NOTE: When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. Refer to the procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair REMOVAL 1. Disconnect negative cable from the battery. 2. Perform the Fuel Pressure Release Procedure. Refer to procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of the fuel tube nipple. The retainer will remain on the fuel tube. INSTALLATION 1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. Fig. 21 Plastic Quick-Connect Fitting/Fuel Tube Connection Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 5009 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. - The quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. - If they are not visible, the retainer was not properly installed (Fig. 21). - Do not rely upon the audible click to confirm a secure connection. 4. Ensure the locking ears on the retainer and the shoulder (stop bead) on the fuel tube are completely visible in the quick-connect fitting windows. Do not rely upon the audible click to confirm a secure connection. Always pull on the line and fitting to ensure that retainer is seated. 5. Verify the connection by pulling on the lines. If the fitting locks in place, the connection is secure. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 6. Use the DRB or equivalent scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Without Vacuum Connected to Regulator ..................................................................................................................... 324 to 343 kPa (47 to 50 psi) With Vacuum Connected to Regulator ...................................................................................................................... Approximately 265 kPa (38 psi) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5013 Fuel Pressure Regulator: Description and Operation Fig. 15 Fuel Pressure Regulator PURPOSE The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 330 kPa (48 psi). OPERATION The fuel pressure regulator is part of the fuel pump module (Fig. 15). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5014 Fuel Pressure Regulator: Service and Repair Fig. 15 Fuel Pressure Regulator Fig. 16 Fuel Pressure Regulator Removal NOTE: The fuel pressure regulator is part of the fuel pump module (Fig. 15). Remove the fuel pump module from the fuel tank for to access the fuel pressure regulator. REMOVAL 1. Spread tangs on pressure regulator retainer (Fig. 15). 2. Pry fuel pressure regulator out of housing (Fig. 16). 3. Ensure both upper and lower 0-rings were removed with regulator. Fig. 17 Fuel Pressure Regulator O-rings INSTALLATION 1. Lightly lubricate the 0-rings with engine oil and place them into opening in pump module (Fig. 17). 2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over tabs on housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel pump relay is located in the power distribution center, at the lefthand side of the engine compartment and behind the battery. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Fuel Pump Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5045 Fuel Pump Relay: Description and Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5046 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5047 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > NHTSA96V228000 > Nov > 96 > Recall 96V228000: Brake & Fuel Line Corrosion Fuel Supply Line: Recalls Recall 96V228000: Brake & Fuel Line Corrosion The fuel and rear brake tubes can experience accelerated corrosion between the tubes and a rubber isolator. Corrosion of the tubes can lead to brake fluid or fuel leakage. This can cause a loss of brakes or result in a fire. Dealers will inspect the brake, fuel supply and fuel vapor tubes for the presence of corrosion. Any tubes showing corrosion will be replaced. All vehicles will have the rubber isolator replaced with a plastic clip. Owner notification began December 6, 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5060 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5061 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5062 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5063 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5064 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5065 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 5066 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > NHTSA96V228000 > Nov > 96 > Recall 96V228000: Brake & Fuel Line Corrosion Fuel Supply Line: All Technical Service Bulletins Recall 96V228000: Brake & Fuel Line Corrosion The fuel and rear brake tubes can experience accelerated corrosion between the tubes and a rubber isolator. Corrosion of the tubes can lead to brake fluid or fuel leakage. This can cause a loss of brakes or result in a fire. Dealers will inspect the brake, fuel supply and fuel vapor tubes for the presence of corrosion. Any tubes showing corrosion will be replaced. All vehicles will have the rubber isolator replaced with a plastic clip. Owner notification began December 6, 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5076 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5077 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5078 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5079 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5080 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5081 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 5082 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fig. 6 Fuel Filler Neck Removal/Installation 1. Loosen fuel filler tube cap. 2. Remove fuel filler neck screws (Fig. 6). 3. Disconnect fuel filler tube from filler neck. Remove filler neck. 4. Reverse for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: Customer Interest Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 5100 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Fuel Tank Sending Unit Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation Fuel Gauge Sender: Description and Operation Fuel Level Sensor Operation FUEL LEVEL SENSOR Circuit G4 connects the fuel-level sensor to the fuel gauge in the instrument cluster, and splices to the Powertrain Control Module (PCM). The fuel-level sensor is a variable resistor. Circuit G5 from the fuse block supplies voltage to the fuel gauge. The fuel-level sensor draws voltage from circuit G5 through the fuel gauge on circuit G4. Circuit Z2 provides the ground path for the fuel-level sensor. The grounding point for circuit Z2 is the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 5121 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too High NAME OF CODE: Fuel Level Sending Unit Volts Too High WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes above a calculated value. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating a low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 5122 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too Low NAME OF CODE: Fuel Level Sending Unit Volts Too Low WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes below 0.75 volt. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low speeds. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 5123 Fuel Gauge Sender: Description and Operation Fuel Level Unit No Change Over Miles NAME OF CODE: Fuel Level Unit No Change Over Miles WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 does not change a calibrated amount over a calculated number of miles. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration Fuel Gauge Sender: Testing and Inspection Test For Sending Unit Opration Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 5126 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 5127 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Helpful Information Gas current flows through coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel-level sensor contains a variable resistor. As the position of the float arm on the fuel-level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. ^ Circuit G4 connects to cavity 13 of the Powertrain Control Module (PCM) connector. The PCM determines low fuel level from circuit G4. Refer to Group 14 for fuel system operation. ^ Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 10 of the PCM, and cavity 2 of the TPS connector. ^ The PCM provides a ground for the throttle position sensor signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 3 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 5128 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Testing Fig. 6 Level Sensor Diagnosis OPERATION This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Refer to the electrical diagrams for circuit identification. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. PROCEDURE 1. Connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. 2. Move the float lever to the positions shown in the resistance chart. 3. Record the resistance at each point. - Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 5129 Fuel Gauge Sender: Testing and Inspection Fuel Pump Module Helpful Information Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 5130 Fuel Gauge Sender: Service and Repair Fig. 7 Fuel Pump/Level Sensor Electrical Connector REMOVAL 1. Remove fuel pump module. Refer to procedure. 2. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 8 Wire Terminal Locking Wedge 3. Pull off blue locking wedge. Fig. 9 Wire Terminal Locking Finger 4. Using a small screwdriver lift locking finger away from terminal and push terminal out 6f connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 5131 Fig. 10 Removing Wires From Connector 5. Push level sensor signal and ground terminals out of the connector. Fig. 11 Loosening Level Sensor 6. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Fig. 12 Level Sensor Removal/Installation 7. Slide level sensor wires through opening fuel pump module. 8. Slide level sensor out of installation channel in module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 5132 Fig. 13 Groove In Back Side Of Level Sensor INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. Fig. 14 Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Specifications Fuel Tank Mounting Straps: Specifications Fuel Tank Straps torque = 23 Nm (250 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor Torque = 3 Nm (25 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5139 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Idle Air Control Motor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Motor Operation NAME OF CODE: Idle Air Control Motor Circuits WHEN MONITORED: With the ignition ON, battery voltage greater than 10.0 volts, and the idle air control motor (IAC) active. SET CONDITION: The Powertrain Control Module (PCM) senses a short to ground or battery voltage on any of the four IAC driver circuits for 2.75 seconds while the IAC motor is active. THEORY OF OPERATION: The idle air control motor is used by the PCM to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. POSSIBLE CAUSES: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor NOTE: The PCM cannot detect an open driver circuit or a stuck motor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation > Page 5161 Idle Speed/Throttle Actuator - Electronic: Description and Operation Target Idle Not Reached (+/200 RPM) NAME OF CODE: Target Idle Not Reached (+/- 200 RPM) WHEN MONITORED: Engine idling and the brake ON. There must not be a manifold absolute pressure (MAP) sensor trouble code or a throttle position sensor trouble code. SET CONDITION: Engine idle is not within 200 RPM of target idle for 2.96 milliseconds. THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. POSSIBLE CAUSES: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor - Carbon deposits - Driver circuit open Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Operation > Page 5162 Idle Speed/Throttle Actuator - Electronic: Description and Operation Vacuum Leak Found (IAC Fully Seated) NAME OF CODE: Vacuum Leak Found (IAC Fully Seated) WHEN MONITORED: With the engine running. SET CONDITION: The MAP sensor signal does not correlate to the TP sensor signal. THEORY OF OPERATION: The PCM monitors the MAP signal as well as the TP sensor signal. The vacuum reading decreases as throttle opening increases proportionally. The PCM compares the two values to verify the relation between the two signals. POSSIBLE CAUSES: - Vacuum Leak - Faulty MAP sensor - Faulty TP sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 5163 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 14 Throttle Position Sensor And Idle Air Control Motor NOTE: The idle air control motor attaches to the side of the throttle body (Fig. 14). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body. Refer to procedure. 4. Remove idle air control motor mounting screws. 5. Remove idle air control motor. Ensure 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB or equivalent AIS Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 3 Nm (25 in lb) torque. 4. Install throttle body. Refer to procedure. 5. Attach electrical connectors to idle air control motor and throttle position sensor. 6. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 5188 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 5189 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 5190 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 5191 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel pump relay is located in the power distribution center, at the lefthand side of the engine compartment and behind the battery. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Fuel Pump Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5215 Fuel Pump Relay: Description and Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5216 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5217 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Auto Shut Down Relay Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation Automatic Shut Down (ASD) Relay: Description and Operation ASD Relay Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 5242 Automatic Shut Down (ASD) Relay: Description and Operation ASD Sense Circuit-PCM Input PURPOSE The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. OPERATION When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > ASD Relay Operation > Page 5243 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Code Messages & Set Conditions Auto Shutdown Relay Control Circuit NAME OF CODE: Auto Shutdown Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the auto shutdown relay control circuit. THEORY OF OPERATION: The automatic shutdown relay (ASD) controls the 12-volt source to the fuel injectors, ignition coils, and the generator. If the vehicle is equipped with a power distribution center (PDC), the relay will be located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - inoperative circuit driver in powertrain control module No ASD Relay Output Voltage at PCM NAME OF CODE: No ASD Relay Output Voltage At PCM WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: No voltage sensed at the powertrain control module (PCM) when the auto shutdown relay (ASD) is energized. THEORY OF OPERATION: When the ASD relay is energized, the relay's contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. POSSIBLE CAUSES: - ASD relay output circuit open - ASD relay - Fused B(+) circuit open - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 5244 Automatic Shut Down (ASD) Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Page 5245 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Description and Operation Rollover/Pressure Relief Valve: Description and Operation Fig. 7 Fuel Filler Tube Rollover Valve These vehicles have two rollover valves. One in the fuel filler tube. - And one on the top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Description and Operation > Page 5249 Rollover/Pressure Relief Valve: Testing and Inspection Gently shake the valve -- up and down. If the float valve can be heard moving -- knocking -- then the valve is OK. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve Replacement Rollover/Pressure Relief Valve: Service and Repair Fuel Filler Tube Rollover Valve Replacement Fig. 7 Fuel Filler Tube Rollover Valve NOTE: The rollover valve is mounted in the fuel filler tube (Fig. 7). REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Disconnect vapor tube from rollover valve. 3. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve Replacement > Page 5252 Rollover/Pressure Relief Valve: Service and Repair Fuel Tank Rollover Valve Replacement REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Remove fuel tank. Refer to procedure. 3. Disconnect vapor tube from rollover valve. 4. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel tank. Refer to procedure. See: Fuel Tank/Service and Repair/Fuel Tank Replacement 5. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 5262 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 5268 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 5274 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 5280 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 5283 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5284 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 5306 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 5307 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5310 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 5311 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 5312 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS MIL ON/DTC MIL 24 Set Throttle Body: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS MIL ON/DTC MIL 24 Set > Page 5321 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 182095A > Dec > 95 > Throttle Body High Effort to Move Accelerator Pedal Throttle Body: Customer Interest Throttle Body - High Effort to Move Accelerator Pedal NO: 18-20-95 Rev. A GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Increased Throttle Effort to Move Accelerator Pedal from Idle Position Note: This Bulletin supersedes Technical Service Bulletin 18-20-95 dated June 9, 1995 which should be removed from your files. Repair procedure (B) has been added to reprogram the Powertrain Control Module. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Increased effort required to move the accelerator pedal from the idle position. DIAGNOSIS: Inspect the accelerator pedal attachment, throttle cable routing and attachments at the throttle body. If there are no kinks, binds or other obstructions that would contribute to increased throttle pedal effort, proceed to the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 4318037 Mopar Brake Parts Cleaner AR 4669034 Throttle Body Base Gasket (used only with vehicles equipped with aluminum intake manifold) 1 NPN Scotch Brite Pad (Green) or Equivalent 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE (A): This bulletin involves removing the throttle body and cleaning any residue that has accumulated on the throttle blade and throttle body bore. In addition, this bulletin also involves erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Remove the throttle body from the engine. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, P/N 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. NOTE: Use only Mopar Brake Parts Cleaner P/N 4318037 as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 3. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade. NOTE: It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle blade and the portion of the throttle body bore that is in the closest proximity of the closed throttle blade are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with Mopar Brake Parts Cleaner, P/N 4318037, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 182095A > Dec > 95 > Throttle Body High Effort to Move Accelerator Pedal > Page 5326 Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle blade on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the effort still exists, then some other condition exists with the throttle body and/or linkage and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body back on the engine. NOTE: The Mopar Diagnostic System (MDS) is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE (B): This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the EGR system below 10° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Throttle Body, Remove and Clean Labor Operation No: 14-30-02-93 ....................................................................................................... ................................................................ 0.6 Hrs. Remove and Clean 1995 PL Residue from Throttle Body Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 182095A > Dec > 95 > Throttle Body High Effort to Move Accelerator Pedal > Page 5327 and Bore FAILURE CODE: XX - Service Adjustment Powertrain Control Module Update Labor Operation No: 08-19-43-91 ....................................................................................................... ................................................................ 0.5 Hrs. Module, Powertrain 1995 PL Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Body: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 5333 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal Throttle Body: All Technical Service Bulletins Throttle Body - High Effort to Move Accelerator Pedal NO: 18-20-95 Rev. A GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Increased Throttle Effort to Move Accelerator Pedal from Idle Position Note: This Bulletin supersedes Technical Service Bulletin 18-20-95 dated June 9, 1995 which should be removed from your files. Repair procedure (B) has been added to reprogram the Powertrain Control Module. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Increased effort required to move the accelerator pedal from the idle position. DIAGNOSIS: Inspect the accelerator pedal attachment, throttle cable routing and attachments at the throttle body. If there are no kinks, binds or other obstructions that would contribute to increased throttle pedal effort, proceed to the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 4318037 Mopar Brake Parts Cleaner AR 4669034 Throttle Body Base Gasket (used only with vehicles equipped with aluminum intake manifold) 1 NPN Scotch Brite Pad (Green) or Equivalent 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE (A): This bulletin involves removing the throttle body and cleaning any residue that has accumulated on the throttle blade and throttle body bore. In addition, this bulletin also involves erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Remove the throttle body from the engine. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, P/N 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. NOTE: Use only Mopar Brake Parts Cleaner P/N 4318037 as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 3. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade. NOTE: It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle blade and the portion of the throttle body bore that is in the closest proximity of the closed throttle blade are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with Mopar Brake Parts Cleaner, P/N 4318037, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5338 Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle blade on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the effort still exists, then some other condition exists with the throttle body and/or linkage and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body back on the engine. NOTE: The Mopar Diagnostic System (MDS) is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE (B): This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the EGR system below 10° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Throttle Body, Remove and Clean Labor Operation No: 14-30-02-93 ....................................................................................................... ................................................................ 0.6 Hrs. Remove and Clean 1995 PL Residue from Throttle Body Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5339 and Bore FAILURE CODE: XX - Service Adjustment Powertrain Control Module Update Labor Operation No: 08-19-43-91 ....................................................................................................... ................................................................ 0.5 Hrs. Module, Powertrain 1995 PL Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 5340 Throttle Body: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 5341 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission Throttle Body: Service and Repair Automatic Transmission Fig. 5 Throttle Body Cables Attachment To Throttle Body Fig. 6 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable from throttle body cam (Figs. 5 and 6). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). Fig. 7 Transmission Kickdown Cable Connector 3. Hold throttle lever in the wide open position. Using finger pressure only, remove kickdown cable by PUSHING connector off the lever nail head (Figs. 5 and 7). DO NOT try to pull connector off perpendicular to the lever. 4. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 5344 Fig. 8 Speed Control Cable Connector 5. If equipped with speed control, hold throttle lever in the wide open position. Using finger pressure only, remove speed control cable by PUSHING connector off the lever nail head (Figs. 5 and 8). DO NOT try to pull connector off perpendicular to the lever. 6. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). 7. Remove 2 screws holding cable mounting bracket and support bracket. 8. Remove throttle body mounting bolts. Remove throttle body Fig. 9 Re-Usable Throttle Body Gasket 9. The rubber 0-ring gasket on the intake manifold is reusable. Wipe the 0-ring clean before installing throttle body (Fig. 9). INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts. 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Install cable housing(s) retainer tabs -into bracket. 4. Install throttle body cables using the following procedures. 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install throttle cable clasp (Fig. 6). 6. If equipped with speed control, rotate throttle lever forward to the wide open position and slide speed control cable connector onto nail head. 7. Rotate throttle lever forward to the wide open position and slide kickdown cable connector onto nail head. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 5345 Throttle Body: Service and Repair Manual Transmission Fig. 3 Throttle Cable Attachment To Throttle Body Fig. 4 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable from the throttle body lever (Figs. 3 and 4). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 4). 3. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable. INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts. 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Install cable housing(s) retainer tabs into bracket. 4. Install throttle body cables using the following procedures. 5. If equipped with speed control, rotate the throttle lever forward to the wide open position and install speed control cable clasp (Fig. 4). 6. Rotate throttle lever to wide open position and install throttle cable clasp (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Cable: > 141294 > Jun > 94 > Accelerator Pedal - Vibration While Driving Accelerator Cable: Customer Interest Accelerator Pedal - Vibration While Driving NO: 14-12-94 GROUP: Fuel DATE: Jun. 6, 1994 SUBJECT: Accelerator Pedal Vibration MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO THE FOLLOWING VEHICLES: AUTOMATIC TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-11-XX. MANUAL TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-18-XX. SYMPTOM/CONDITION: Automatic and Manual Transmission - Vibration felt through the accelerator pedal at 3000 to 3500 RPM's while driving. Manual Transmission - Vibration felt through the accelerator pedal at idle or low engine RPM's while driving. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4669467 Throttle Cable Assembly - Man. Trans. 1 4669468 Throttle Cable Assembly - Auto. Trans. REPAIR PROCEDURE: This bulletin involves removal, replacement and rerouting of the throttle cable assembly. 1. Following the procedures outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-14 and 14-15, replace the throttle cable assembly with the appropriate new cable listed in the parts section of this bulletin. NOTE: ROUTE THE NEW THROTTLE CABLE ASSEMBLY INBOARD OF THE HEATER HOSES, UNDERNEATH THE AIR CLEANER FRESH AIR DUCT AND OVER THE TOP OF THE SPEED CONTROL CABLE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-80-25-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Cable: > 141294 > Jun > 94 > Accelerator Pedal - Vibration While Driving Accelerator Cable: All Technical Service Bulletins Accelerator Pedal - Vibration While Driving NO: 14-12-94 GROUP: Fuel DATE: Jun. 6, 1994 SUBJECT: Accelerator Pedal Vibration MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO THE FOLLOWING VEHICLES: AUTOMATIC TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-11-XX. MANUAL TRANSMISSION EQUIPPED BUILT PRIOR TO MDH 04-18-XX. SYMPTOM/CONDITION: Automatic and Manual Transmission - Vibration felt through the accelerator pedal at 3000 to 3500 RPM's while driving. Manual Transmission - Vibration felt through the accelerator pedal at idle or low engine RPM's while driving. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4669467 Throttle Cable Assembly - Man. Trans. 1 4669468 Throttle Cable Assembly - Auto. Trans. REPAIR PROCEDURE: This bulletin involves removal, replacement and rerouting of the throttle cable assembly. 1. Following the procedures outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-14 and 14-15, replace the throttle cable assembly with the appropriate new cable listed in the parts section of this bulletin. NOTE: ROUTE THE NEW THROTTLE CABLE ASSEMBLY INBOARD OF THE HEATER HOSES, UNDERNEATH THE AIR CLEANER FRESH AIR DUCT AND OVER THE TOP OF THE SPEED CONTROL CABLE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-80-25-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Automatic Transmission Accelerator Cable: Service and Repair Automatic Transmission Fig. 5 Throttle Body Cables Attachment To Throttle Body Fig. 6 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove throttle cable from throttle body cam (Figs. 5 and 6). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Automatic Transmission > Page 5361 Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 3. From inside the vehicle, hold the throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft (Fig. 1 and Fig. 2). 4. Remove retainer clip from throttle cable and grommet at the dash panel (Fig. 2). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer (Fig. 2). 4. Install cable retainer clip (Fig. 2). 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 6). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Automatic Transmission > Page 5362 Accelerator Cable: Service and Repair Manual Transmission Fig. 3 Throttle Cable Attachment To Throttle Body Fig. 4 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove the throttle cable from the throttle body lever (Figs. 3 and 4). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 4). Fig. 1 Accelerator Pedal And Throttle Cable -- Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Automatic Transmission > Page 5363 Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 3. From inside the vehicle, hold the accelerator pedal up and remove the cable retainer and cable from upper end of pedal shaft (Figs. 1 and 2). 4. Remove retainer clip from throttle cable and grommet at the dash panel (Fig. 2). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer (Fig. 2). 4. Install cable retainer clip (Fig. 2). 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 5372 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 5378 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 5381 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (17 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5382 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Throttle Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Throttle Position Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- approximately 0.5 volts. - AT Wide open throttle -- maximum of 3.7 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 5404 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions No 5 Volts to TP Sensor NAME OF CODE: No 5 Volts to TP Sensor WHEN MONITORED: Vehicle speed above 20 mph, MAP sensor vacuum above 3 in., and engine speed above 1500 rpm. SET CONDITION: TP sensor signal goes below 0.5 volts. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position ;under all operating conditions. - The TP sensor receives a 5 volt supply from PCM cavity 61. - The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5 volt supply - TP sensor failure Throttle Position Sensor Operation THROTTLE POSITION SENSOR From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 43 of the PCM, and cavity 1 of the sensor connector. When the operator puts the vehicle in reverse, the back-up lamp switch connects circuits F20 and L1. Circuit F20 is connected to a bus bar in fuse block, and cavity 3 of the PARK/NEUTRAL position switch. Circuit A22 feeds the bus bar. Circuit L1 feeds the back-up lamps and double-crimps to provide an input to the PCM on cavity 55. Circuit L1 connects to cavity 1 of the PARK/NEUTRAL position switch. Throttle Position Sensor Voltage High NAME OF CODE: Throttle Position Sensor Voltage High WHEN MONITORED: With the ignition ON. SET CONDITION: Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes above 4.5 volts for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 5405 SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 10 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP NAME OF CODE: TPS Voltage Does Not Agree with MAP WHEN MONITORED: With the engine running. SET CONDITION: The powertrain control module (PCM) performs two separate tests on the Throttle Position (TP) sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 MPH and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 2.8 seconds. THEORY OF OPERATION: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 43. The sensor ground is provided by PCM cavity 51. POSSIBLE CAUSES: - Failed powertrain control module - TP sensor failure - Sensor miswired - Mechanical failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5408 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be approximately 0.5 volts. - At wide open throttle, TPS output voltage should be approximately 3.7 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 5409 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 5410 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (17 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 5425 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5426 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5448 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5449 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5450 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5453 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5454 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 5455 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5459 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5481 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5482 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5483 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5484 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5485 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 5488 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 5489 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 5493 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5496 Ignition Cable: Component Tests and General Diagnostics Testing Fig. 4 Setting Spark Plug Electrode Gap TESTING USING AN OSCILLOSCOPE When testing cables for punctures and cracks with an oscilloscope, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during test or possible heat damage to catalytic converter will occur. Total test time must not exceed one minute. NOTE: Test must be performed at idle only. IF AN OSCILLOSCOPE IS NOT AVAILABLE, TEST CABLES AS FOLLOWS: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Cracked, leaking or faulty cables should be replaced. 3. Use an ohmmeter to check cables for opens, loose terminals or high resistance. a. Remove cable from spark plug. b. Remove cable from the coil tower. c. Connect the ohmmeter between spark plug end terminal and the coil end terminal. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in same manner. CABLE RESISTANCE CHART MINIMUM MAXIMUM 250 Ohms/Inch 1,000 Ohms/Inch 3,000 Ohms/Foot 12,000 Ohms/Foot Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 1,000 Ohms per Inch 3,000 Ohms per Foot 12,000 Ohms per Foot Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5497 Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 5500 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. On SOHC engines, be sure that dual plastic clip holds #1, #2 cables off of valve cover and that PCV hose plastic clip holds #3 cable away from metal PCV clamp and edge of air duct. On DOHC, be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Resistance Primary @ 21-27°C (70-80°F) ........................................................................................................................................................ 0.51 to 0.61 ohms Secondary @ 21-27°C (70-80°F) ............................................................................................................................................ 11,500 to 13,500 ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 5505 Ignition Coil: Mechanical Specifications Ignition Coil to Bracket Torque ............................................................................................................ .................................................... 12 Nm (105 in lb) Ignition Coil Bracket to Cyl. Head Torque ............................................................................................................................................... 22 Nm (200 in lb) Ignition Coil Bracket Nuts .................................................................................................................... ................................................... 22 Nm (200 in lbs) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5506 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Ignition Coil: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 Ignition Coil: Electrical Diagrams Coil Primary Circuit Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5526 Ignition Coil: Description and Operation WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. OPERATION The coil pack consists of 2 coils molded together. The coil pack is mounted on a bracket, over the valve cover (Fig. 17). High tension leads route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression - The other cylinder fires on the exhaust stroke. Coil number one fires cylinders 1 and 4. Coil number two fires cylinders 2 and 3. The PCM determines which of the coils to charge and fire at the correct time. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. CIRCUIT DESCRIPTION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut-Down ( ASD) relay connects circuit A14 and circuit A142. A 20 amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 18 of the PCM connector. Circuit A142 supplies voltage for the ignition coil pack through cavity 2 of the ignition coil connector. The coil pack consists of two individual coils molded together. The PCM controls the ground circuit of each coil. - Circuit K17 is the ground circuit for the ignition coil that fires spark plugs # 1 and # 4. Circuit K17 connects to cavity 21 of the PCM and to cavity 3 of the ignition coil connector. - Circuit K19 is the ground circuit for the ignition coil that fires spark plugs # 2 and # 3. Circuit K19 connects to cavity 1 of the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information Ignition Coil: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, Automatic Shut-Down (ASD) relay, generator, up-stream heated oxygen sensor and downstream heated oxygen sensor. The Powertrain Control Module (PCM) controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 5529 Ignition Coil: Testing and Inspection Ignition Coil Test Fig. 2 Terminal Identification Fig. 3 Checking Ignition Coil Secondary Resistance Coil one fires cylinders 1 and 4, coil two fires cylinders 2 and 3. Each coil tower is labeled with the number of the corresponding cylinder. 1. Remove the ignition cables and measure the resistance of the cables. Resistance must be between 3,000 to 12,000 ohms per foot of cable. Replace any cable not within tolerance. 2. Disconnect the electrical connector from the coil pack. 3. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question (Fig. 2). Resistance on the primary side of each coil should be 0.51 - 0.61 ohm. Replace the coil if resistance is not within tolerance. 4. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil (Fig. 3). Secondary resistance should be 11,500 to 13,500 ohms. Replace the coil if resistance is not within tolerance. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 5530 Ignition Coil: Service and Repair Fig. 15 Electronic Ignition Coil Pack NOTE: The electronic ignition coil pack attaches to a bracket mounted on top of the cylinder head cover (Fig. 15). REMOVAL 1. Disconnect electrical connector from coil pack. 2. Remove coil pack mounting nuts. 3. Remove coil. 4. Install coil pack on bracket. 5. Transfer spark plug cables to new coil pack. - The coil pack towers are numbered with the cylinder identification. NOTE: Be sure the ignition cables snap onto the towers. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 5534 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 5554 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 5557 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 5565 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5566 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig. 5 Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 5) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5588 OPERATION The camshaft position sensor attaches to the rear of the cylinder head (Fig. 5). A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the camshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector, and cavity 3 of the camshaft position sensor. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 26 of the PCM, and cavity 1 of the camshaft position sensor. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and cavity 2 of the camshaft position sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5589 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 5590 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM NAME OF CODE: No Cam Signal at PCM WHEN MONITORED: During engine cranking, after a number of crank position sensor signals have been detected. SET CONDITION: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor. THEORY OF OPERATION: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the the south pole passes under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Crankshaft position sensor ^ Battery temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Engine coolant temperature sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5593 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 5594 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 5595 Camshaft Position Sensor: Service and Repair Fig. 8 Camshaft Position Sensor Location NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air tube from the oil separator hose. Remove filtered air tube. 2. Remove the air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove brake booster hose and electrical connector from holders on end of cylinder head cover. 5. Remove camshaft position sensor mounting screws. Remove sensor. Fig. 9 Target Magnet Removal/Installation 6. Loosen screw attaching target magnet to rear of camshaft (Fig. 9). INSTALLATION NOTE: The target magnet has a locating dowel that fits into a machined locating hole in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 5. Install air cleaner inlet tube and filtered air tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5599 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Camshaft And Crankshaft Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Operation Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60 degree signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees before top dead center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5621 Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5622 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 8 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. OPERATION The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch (Fig. 8). From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69 degrees Before Top Dead Center (BTDC). - The second notch represents 49 degrees BTDC. - The third notch represents 29 degrees. - The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 200 increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. If available, an oscilloscope can display the square wave patterns of each voltage pulse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5623 Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 9-volt supply circuit that feeds both sensors. Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5624 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP NAME OF CODE: Intermittent Loss of CMP or CKP WHEN MONITORED: During engine running. SET CONDITION: When the expected cam signal level disagrees with the actual cam signal level. THEORY OF OPERATION: The camshaft sensor is a hall effect type sensor. After the engine has been started, the Powertrain Control Module (PCM) maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. POSSIBLE INTERMITTENT CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor Operation > Page 5625 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM NAME OF CODE: No Crank Reference Signal at PCM WHEN MONITORED: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. SET CONDITION: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. THEORY OF OPERATION: The crankshaft position sensor is a hall-effect type sensor used to detect the crankshaft's speed and position. The Powertrain Control Module (PCM) supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. POSSIBLE CAUSES: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig. 24 Square Wave Pattern In Crankshaft Degrees This no-start test checks the camshaft position sensor and crankshaft position sensors. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the ON position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the controller de-energizes the relay within one second if it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a crankshaft position sensor signal. If a crank or cam signal is missing during cranking, the respective DTC will be set within 11 seconds. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. Fig. 25 Coil Harness Connector 2. Disconnect the harness connector from the coil pack (Fig. 25). CAUTION: When testing the various sensors, be sure that the harness wires are not damaged by the test meter probes. 3. Touch a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. - The center terminal of the connector supplies battery voltage. 4. Turn the ignition key to the ON position. The test light should flash On and then Off. Do not turn the Key to the OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the auto shutdown (ASD) relay Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or equivalent scan tool to test the ASD relay and circuits. Refer to the electrical diagrams for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the On position before cranking. Wait for the test light to flash once then crank the engine.) a. If the test light momentarily flashes during cranking, the PCM is not receiving a camshaft position sensor signal. Use the DRB or equivalent Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 5628 scan tool to test the camshaft position sensor and sensor circuits. Refer to the electrical diagrams for circuit information. b. If the test light did not flash during cranking, unplug the camshaft position sensor connector. Turn the ignition key to the OFF position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. - If the test light momentarily flashes, the camshaft position sensor is shorted and must be replaced. - If the light did not flash when the engine was cranked, the cause of the no-start is in either the crankshaft position sensor/camshaft position sensor 8-volt supply circuit, or the crankshaft position sensor 5-volt output or ground circuits. Use the DRB or equivalent scan tool to test the crankshaft position sensor and the sensor circuits. Refer to the electrical diagrams for circuit information. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 5629 Crankshaft Position Sensor: Service and Repair Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 5634 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 5635 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 5636 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications Detonation (Knock) Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Specifications > Page 5640 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions Detonation (Knock) Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Detonation (Knock) Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Knock Sensor Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Diagrams > Page 5660 Detonation (Knock) Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 27 of the PCM, and cavity 2 of the sensor connector. The PCM provides a ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 1 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Helpful Information Detonation (Knock) Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Intake air temperature sensor ^ Manifold absolute pressure sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Testing and Inspection > Page 5663 Detonation (Knock) Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 5668 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 5671 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 5672 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5673 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5674 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5677 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5678 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5679 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5680 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5681 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5682 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5683 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 5684 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 5685 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 5686 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 5695 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5696 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5697 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5726 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5737 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5738 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5739 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal PROM - Programmable Read Only Memory: Customer Interest Throttle Body - High Effort to Move Accelerator Pedal NO: 18-20-95 Rev. A GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Increased Throttle Effort to Move Accelerator Pedal from Idle Position Note: This Bulletin supersedes Technical Service Bulletin 18-20-95 dated June 9, 1995 which should be removed from your files. Repair procedure (B) has been added to reprogram the Powertrain Control Module. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Increased effort required to move the accelerator pedal from the idle position. DIAGNOSIS: Inspect the accelerator pedal attachment, throttle cable routing and attachments at the throttle body. If there are no kinks, binds or other obstructions that would contribute to increased throttle pedal effort, proceed to the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 4318037 Mopar Brake Parts Cleaner AR 4669034 Throttle Body Base Gasket (used only with vehicles equipped with aluminum intake manifold) 1 NPN Scotch Brite Pad (Green) or Equivalent 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE (A): This bulletin involves removing the throttle body and cleaning any residue that has accumulated on the throttle blade and throttle body bore. In addition, this bulletin also involves erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Remove the throttle body from the engine. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, P/N 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. NOTE: Use only Mopar Brake Parts Cleaner P/N 4318037 as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 3. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade. NOTE: It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle blade and the portion of the throttle body bore that is in the closest proximity of the closed throttle blade are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with Mopar Brake Parts Cleaner, P/N 4318037, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5744 Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle blade on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the effort still exists, then some other condition exists with the throttle body and/or linkage and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body back on the engine. NOTE: The Mopar Diagnostic System (MDS) is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE (B): This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the EGR system below 10° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Throttle Body, Remove and Clean Labor Operation No: 14-30-02-93 ....................................................................................................... ................................................................ 0.6 Hrs. Remove and Clean 1995 PL Residue from Throttle Body Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5745 and Bore FAILURE CODE: XX - Service Adjustment Powertrain Control Module Update Labor Operation No: 08-19-43-91 ....................................................................................................... ................................................................ 0.5 Hrs. Module, Powertrain 1995 PL Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183695 > Dec > 95 > PCM - EGR Monitor Faults, Cold Sag or Hesitation PROM - Programmable Read Only Memory: Customer Interest PCM - EGR Monitor Faults, Cold Sag or Hesitation NO: 18-36-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: EGR Monitor Faults and/or Sag or Hesitation on Cold Start Below 32 Degrees Fahrenheit. MODELS: 1995 (PL) Neon NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-20-95 Rev. A, 18-38-95, or 18-39-95 dated December 08, 1995. SYMPTOM/CONDITION: Sag or hesitation during operation in ambient temperatures below 32° F., with high humidity, and usually after the vehicle has been sitting overnight. The Check Engine Light may be illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no codes or only DTC "EGR SYSTEM FAILURE" is present and all systems are functioning correctly, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables EGR diagnostics below 32° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183695 > Dec > 95 > PCM - EGR Monitor Faults, Cold Sag or Hesitation > Page 5750 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-90 ......................................................................................................................................... ............................... 0.5 Hrs Module, Powertrain (1995 PL) Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183895 > Dec > 95 > PCM - No Engine Rpm Drop When Shifting PROM - Programmable Read Only Memory: Customer Interest PCM - No Engine Rpm Drop When Shifting NO: 18-38-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Engine RPM Does Not Decrease When Shifting MODELS: 1995 (PL) Neon NOTE: This bulletin applies to manual transaxle equipped vehicles. NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-36-96,18-20-95 Rev. A, or 18-39-95 dated December 08, 1995. SYMPTOM/CONDITION: Engine RPM briefly (1-5 seconds) does not decrease, when the clutch is disengaged and the throttle is closed while shifting. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which reduces the duration that the RPM hangs up. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183895 > Dec > 95 > PCM - No Engine Rpm Drop When Shifting > Page 5755 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-92 ......................................................................................................................................... .............................. 0.5 Hrs. Powertrain Control Module Update FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183995 > Dec > 95 > PCM - Ticking Noise from Engine Compartment PROM - Programmable Read Only Memory: Customer Interest PCM - Ticking Noise from Engine Compartment NO: 18-39-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: "Ticking" Noise from Engine Compartment MODELS: 1995 (PL) Neon NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-36-95,18-20-95 Rev. A, or 18-38-95 dated December 08, 1995. SYMPTOM/CONDITION: Customer complaint of a "ticking" noise at idle from engine compartment. Condition is more noticeable in cold ambient under 40°F. DIAGNOSIS: Disconnect the electrical connector from the Duty Cycle Evap Purge Solenoid, located over the right front engine mount. If the noise goes away, proceed to the Repair Procedure. If a "ticking" noise is still evident, further diagnosis and repair will be necessary which will not be covered in the bulletin. Before continuing, Diagnostic Trouble Code (DTC) "EVAP PURGE SOLENOID CIRCUIT" will have been set and will have to be erased from memory. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the Duty Cycle Evap Purge Solenoid at idle when the ambient temperature is less than 0°F, and delays solenoid operation at idle for 30 minutes when the ambient temperature is between 0°F. and 40°F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183995 > Dec > 95 > PCM - Ticking Noise from Engine Compartment > Page 5760 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-93 ......................................................................................................................................... .............................. 0.5 Hrs. Powertrain Control Module Update FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180395 > Feb > 95 > PCM - MIL ON/IAC DTC Set PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/IAC DTC Set NO: 18-03-95 GROUP: Vehicle Performance EFFECTIVE DATE: Feb. 3, 1995 SUBJECT: Check Engine Light On "Vacuum Leak Found (IAC Fully Seated)" MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC ENGINE AND AUTOMATIC TRANSAXLE. SYMPTOM/CONDITION: Check Engine Light is on, Diagnostic Trouble Code "Vacuum Leak Found (IAC Fully Seated)". DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than "Vacuum Leak Found (IAC Fully Seated)" are present, record them on the repair order for future reference and repair as necessary. NOTE: THE IAC WILL BE FULLY SEATED ONLY WITH A GROSS VACUUM LEAK. THE DIAGNOSTIC ROUTINE IN THE PCM DOES NOT USE IAC DATA IN SETTING THIS FAULT. IF THE IAC CONTROLS THE IDLE SPEED PROPERLY, DO NOT REPLACE IT. Verify that a gross vacuum leak does not exist. With the engine at normal operating temperatures, transmission selector in neutral, using MDS and/or DRBIII, the idle speed should not exceed the target value by more than 50 RPM for more than 10 seconds. If the idle speed is within this limit and only the "Vacuum Leak Found (IAC fully Seated)" DTC is present, proceed with the following repair. EQUIPMENT1PARTS REQUIRED: 1 CH6OOO Scan Tool (DRBIII ) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, then the DTC "Vacuum Leak Found (IAC Fully Seated)" actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180395 > Feb > 95 > PCM - MIL ON/IAC DTC Set > Page 5765 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182694A > Dec > 94 > PCM- Check Engine Light ON/Flash Code 31 PROM - Programmable Read Only Memory: Customer Interest PCM- Check Engine Light ON/Flash Code 31 NO: 18-26-94 Rev. A GROUP: Vehicle Performance DATE: Dec. 23, 1994 SUBJECT: Check Engine Light On "Evap Purge Flow Monitor Failure" - Flash Code 31 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-26-94 DATED DEC. 9, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE MODEL APPLICATION NOTE HAS BEEN REVISED. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR AFTER AUG. 6, 1994 (MDH 08-06-XX) THROUGH NOV. 23, 1994 (MDH 11-23-XX), **AND ALSO APPLIES TO ANY VEHICLE WHERE THE PCM WAS REPLACED USING SERVICE BULLETINS 18-18-94 OR 18-25-94.** SYMPTOM/CONDITION: Check Engine Light on, Diagnostic Trouble Code "Evap Purge Flow Monitor Failure" and/or Flash Code 31 is set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than 31 are present, record them on the repair order for future reference and repair as necessary. Verify that the Purge System is functioning properly. Disconnect the purge solenoid hose at the canister. The line should be free of carbon pellets (a light amount of dust is normal). Start the engine. After about 90 seconds, the Duty Cycle Purge Valve should start to cycle. At the open end of the hose one should feel a steady stream of brief vacuum pulses in response to the pulsing of the valve. This is normal and the purge system is functioning properly. If no other codes other than 31 are present, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves reprogramming the powertrain control module with new software. NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATING WITH RELEASE 15 OR HIGHER INSTALLED. This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182694A > Dec > 94 > PCM- Check Engine Light ON/Flash Code 31 > Page 5770 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle PROM - Programmable Read Only Memory: Customer Interest PCM - Steering Column Shake at Idle NO: 18-25-94 GROUP: Vehicle Performance EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Improved Idle Quality on Cold Start Up MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO OCT. 10, 1994 (MDH 10-10-XX). SYMPTOM/CONDITION: Cold start up steering column shake at idle. Condition most noticeable around ambient temperatures of 40 degrees fahrenheit or below. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS BULLETIN INVOLVES REPROGRAMMING PCM'S ON VEHICLES BUILT ON OR AFTER AUGUST 6, 1994, OR REPLACING PCM'S ON VEHICLES BUILT PRIOR TO AUGUST 5, 1994. VEHICLES BUILT PRIOR TO AUGUST 5, 1994: This repair involves replacing the Powertrain Control Module with a new one that incorporates revised software. NOTE: VEHICLES BUILT PRIOR TO APRIL 6, 1994 MAY NOT BE EQUIPPED WITH A STEERING COLUMN DAMPER. TECHNICAL SERVICE BULLETIN 18-07-94 REV. A, DATED JUL. 22, 1994, PROVIDED THE PROCEDURE TO INSTALL A DAMPER WEIGHT, COOLING MODULE BUSHINGS, AND A SOFTWARE CHANGE TO THE PCM TO IMPROVE IDLE ROUGHNESS. ON THOSE VEHICLES BUILT PRIOR TO APRIL 6, 1994 (MDH 04-06-XX), VERIFY THAT TSB 18-07-94 REV. A WAS APPLIED PRIOR TO PROCEEDING WITH THE REPAIR LISTED IN THIS SERVICE BULLETIN. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle > Page 5775 2. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. VEHICLES BUILT AFTER AUGUST 6, 1994: NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATING WITH RELEASE 15 OR HIGHER INSTALLED. This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle > Page 5776 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-92 Powertrain Control Module - Flash 0.5 Hrs. Failure Code: FM - Flash Module Labor Operation NO: 08-19-02-96 Powertrain Control Module - Replace 0.4 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake PROM - Programmable Read Only Memory: Customer Interest PCM - Idle Roughness/Steering Wheel Shake NO: 18-07-94 Rev. A GROUP: Vehicle Performance DATE: Jul. 22, 1994 SUBJECT: Idle Roughness Accompanied by Steering Wheel Shake THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-94 DATED APR. 29, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN REVISES STEP 15 AND 20. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** . MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 6, 1994 (MDH 04-06-XX). SYMPTOM/CONDITION: Rough running engine during idle accompanied by steering wheel shake. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, repair as necessary, and also perform the following repair. If no codes are present and all systems are functioning correctly, perform the following repair. EQUIPMENT/PARTS REQUIRED: NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the powertrain control module with new software (calibrations), installing a steering wheel damper, replacing the steering wheel clockspring, and, on air conditioning equipped cars, replacing the cooling module lower mounting bushings. 1. Place the front road wheels in the straight ahead position. Rotate the steering wheel one half turn (180 degrees) to the right (clockwise). Lock the column with the ignition lock cylinder. WARNING: BEFORE BEGINNING ANY AIR BAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE, DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THIS WILL DISABLE THE AIR BAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIR BAG COMPONENTS. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the reserve capacitor to discharge. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5781 3. Speed Control Equipped - Remove the two attaching screws for each speed control switch and disconnect the two way electrical connectors. Remove the speed control switches. Non-Speed Control Equipped - Remove the two attaching screws for each pod cover and remove the covers. 4. Remove the 4 screws attaching the steering column cover to the lower instrument panel and remove the trim panel. 5. Remove the 3 screws attaching the steering column cover liner and remove from the lower instrument panel. 6. Remove the 2 air bag module attaching screws from under the steering wheel. WARNING: WHEN HANDLING AN UNDEPLOYED AIR BAG MODULE DURING SERVICING OF THE STEERING COLUMN, THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED. AT NO TIME SHOULD A SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF THE AIR BAG MODULE. WHEN CARRYING A LIVE MODULE, THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF THE MODULE ACCIDENTALLY DEPLOYS. IF AN AIR BAG MODULE IS PLACED ON A BENCH OR OTHER SURFACE, THE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT. 7. Lift the air bag module and disconnect the clockspring electrical lead from the back of the module. Remove the air bag module. 8. Disconnect the clockspring electrical lead from the steering wheel horn switches and wiring harness. 9. Remove the steering wheel retainer nut from the steering column shaft. 10. Remove the steering wheel assembly from column shaft using Puller, Special tool C-3428-B. CAUTION: WHEN INSTALLING PULLER C3428-B, BE SURE BOLTS ARE FULLY SEATED IN THE THREADED PULLER HOLES ON THE STEERING WHEEL. DO NOT BUMP OR HAMMER ON THE STEERING WHEEL OR STEERING COLUMN SHAFT WHEN REMOVING WHEEL FROM THE STEERING COLUMN. 11. Lift up the instrument cluster top cover and the cluster bezel until the clips disengage and separate. 12. Insert a screw driver into the access hole at the lower shroud and depress the cylinder button while rotating the cylinder with the key inserted between the ON and START positions to disengage the cylinder from the column. 13. Pull the key cylinder out. 14. Remove the three lower to upper shroud attaching screws through the bottom of the lower shroud. Separate the upper and lower shrouds. 15. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness and at the base of the clockspring. 16. Unlatch and remove the clockspring assembly from the steering shaft. Discard the clockspring. "NOTE: WHEN INSTALLING A NEW CLOCKSPRING, MAKE SURE THE FRONT WHEELS ARE NOT MOVED.** 17. Install new clockspring. Remove the "T" pin from the clockspring and rotate the clock spring rotor one half turn (180 degrees) to the right (clockwise). Connect the clockspring to the instrument panel harness and ensure that the wiring is properly routed. Check the wiring connectors and locking tabs to make sure they are properly engaged. 18. Install the steering wheel ensuring the flats on the hub align with the clockspring. Pull the horn lead, air bag and speed control leads through the larger slot. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5782 19. Position the new damper weight as shown in Figure 1, and install the steering column shaft retaining nut and tighten until steering wheel is fully seated on the shaft. Torque the steering wheel retaining nut to 54 N-m (40 ft.lbs.). 20. Connect the clockspring lead to the horn switches. Route speed control leads (one to each speed control opening). 21. Install the air bag electrical lead from the clockspring into the connector on the back of the air bag module. NOTE: ** BE SURE CONNECTOR IS SECURELY LATCHED INTO THE AIR BAG MODULE CONNECTOR AND THAT THE WIRE IS ORIENTED TOWARD THE BOTTOM OF THE AIR BAG.** 22. Continue installation of the components that were removed to gain access to the clockspring. Make sure original or correct attaching bolts are used. 23. Refer to the Air Bag System Check listed in the Neon Service Manual (Publication No. 81-270-5025) Page SM-4, to verify that Air Bag is installed and operating properly. NOTE: STEPS 23 THROUGH 26 ARE REQUIRED ONLY ON VEHICLES EQUIPPED WITH AIR CONDITIONING. 24. Remove the 2 upper radiator isolator bracket mounting screws. Loosen the radiator to battery strut attaching screw. 25. Raise the cooling module high enough to free the 2 lower mounting isolator bushings from the front crossmember and support the cooling module in this position. 26. Replace the 2 lower mounting isolator bushings with new bushings. 27. Install the cooling module into the lower mounting brackets. Install and tighten the 2 upper radiator isolator bracket mounting screws to 7.4 N-m (65 in.lbs.). NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING STEPS AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. 28. Connect the Mopar Diagnostic System (MDS) and DRBIII Scan Tool to the vehicle and power them up. 29. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 30. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 31. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 32. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5783 33. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 34. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle cannot be programmed or has already been programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 36. 35. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 36. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover label with a clear plastic sticker. 37. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-95 1.2 Hrs. FAILURE CODE: FC - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 140694B > May > 94 > MIL ON, O2 Sensor DTC's Set PROM - Programmable Read Only Memory: Customer Interest MIL ON, O2 Sensor DTC's Set NO: 14-06-94 Rev. B GROUP: Fuel DATE: May 20, 1994 SUBJECT: Check Engine Light On, Code 21, Up or Downstream 02S Shorted to Voltage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-06-94 REV. A, DATED MAY 6, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN PROVIDES FOR REPROGRAMMING THE POWERTRAIN CONTROL MODULE RATHER THAN REPLACING THE MODULE. THE LABOR OPERATION NO. AND TIME HAVE BEEN REVISED TO REFLECT THIS CHANGE, AND INCORRECT OHS REFERENCES ARE CHANGED TO 02S. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 5, 1994 (MDH 04-05-XX). SYMPTOM/CONDITION: The "Check Engine" light illuminates with flash code # 21, or Diagnostic Trouble Code "Upstream 02S Shorted To Voltage or Downstream 02S Shorted To Voltage" is set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference. If codes other than "Upstream or Downstream 02S Shorted to Voltage" are present, repair as necessary. If the "Upstream or Downstream 02S Shorted To Voltage" is present and all other systems are functioning correctly, proceed with the following repair. **EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the powertrain control module with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 140694B > May > 94 > MIL ON, O2 Sensor DTC's Set > Page 5788 If the controller on the vehicle cannot be programmed or has already been programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. If the condition is still present after reprogramming the Powertrain Control Module, follow the diagnostic procedure for either "Upstream or Downstream 02S Shorted to Voltage" and repair as necessary. NOTE: DO NOT INSTALL ANY GREASE IN THE OXYGEN SENSOR CONNECTOR OR USE ANY SILICONE PRODUCT ON OR NEAR THE OXYGEN SENSOR. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker." 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-96 0.4 Hrs. FAILURE CODE: FC - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5794 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5795 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5796 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5797 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5798 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5799 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5800 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5801 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5802 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5803 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5804 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5805 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5806 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5807 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5808 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5809 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5810 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5811 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5812 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5817 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5818 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 5819 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal PROM - Programmable Read Only Memory: All Technical Service Bulletins Throttle Body - High Effort to Move Accelerator Pedal NO: 18-20-95 Rev. A GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Increased Throttle Effort to Move Accelerator Pedal from Idle Position Note: This Bulletin supersedes Technical Service Bulletin 18-20-95 dated June 9, 1995 which should be removed from your files. Repair procedure (B) has been added to reprogram the Powertrain Control Module. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Increased effort required to move the accelerator pedal from the idle position. DIAGNOSIS: Inspect the accelerator pedal attachment, throttle cable routing and attachments at the throttle body. If there are no kinks, binds or other obstructions that would contribute to increased throttle pedal effort, proceed to the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 4318037 Mopar Brake Parts Cleaner AR 4669034 Throttle Body Base Gasket (used only with vehicles equipped with aluminum intake manifold) 1 NPN Scotch Brite Pad (Green) or Equivalent 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE (A): This bulletin involves removing the throttle body and cleaning any residue that has accumulated on the throttle blade and throttle body bore. In addition, this bulletin also involves erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Remove the throttle body from the engine. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, P/N 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. NOTE: Use only Mopar Brake Parts Cleaner P/N 4318037 as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 3. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade. NOTE: It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle blade and the portion of the throttle body bore that is in the closest proximity of the closed throttle blade are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with Mopar Brake Parts Cleaner, P/N 4318037, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5824 Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle blade on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the effort still exists, then some other condition exists with the throttle body and/or linkage and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body back on the engine. NOTE: The Mopar Diagnostic System (MDS) is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE (B): This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the EGR system below 10° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Throttle Body, Remove and Clean Labor Operation No: 14-30-02-93 ....................................................................................................... ................................................................ 0.6 Hrs. Remove and Clean 1995 PL Residue from Throttle Body Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182095A > Dec > 95 > Throttle Body - High Effort to Move Accelerator Pedal > Page 5825 and Bore FAILURE CODE: XX - Service Adjustment Powertrain Control Module Update Labor Operation No: 08-19-43-91 ....................................................................................................... ................................................................ 0.5 Hrs. Module, Powertrain 1995 PL Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183695 > Dec > 95 > PCM - EGR Monitor Faults, Cold Sag or Hesitation PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - EGR Monitor Faults, Cold Sag or Hesitation NO: 18-36-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: EGR Monitor Faults and/or Sag or Hesitation on Cold Start Below 32 Degrees Fahrenheit. MODELS: 1995 (PL) Neon NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-20-95 Rev. A, 18-38-95, or 18-39-95 dated December 08, 1995. SYMPTOM/CONDITION: Sag or hesitation during operation in ambient temperatures below 32° F., with high humidity, and usually after the vehicle has been sitting overnight. The Check Engine Light may be illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no codes or only DTC "EGR SYSTEM FAILURE" is present and all systems are functioning correctly, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables EGR diagnostics below 32° F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183695 > Dec > 95 > PCM - EGR Monitor Faults, Cold Sag or Hesitation > Page 5830 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-90 ......................................................................................................................................... ............................... 0.5 Hrs Module, Powertrain (1995 PL) Control - Reprogram FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183895 > Dec > 95 > PCM - No Engine Rpm Drop When Shifting PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - No Engine Rpm Drop When Shifting NO: 18-38-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: Engine RPM Does Not Decrease When Shifting MODELS: 1995 (PL) Neon NOTE: This bulletin applies to manual transaxle equipped vehicles. NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-36-96,18-20-95 Rev. A, or 18-39-95 dated December 08, 1995. SYMPTOM/CONDITION: Engine RPM briefly (1-5 seconds) does not decrease, when the clutch is disengaged and the throttle is closed while shifting. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which reduces the duration that the RPM hangs up. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183895 > Dec > 95 > PCM - No Engine Rpm Drop When Shifting > Page 5835 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-92 ......................................................................................................................................... .............................. 0.5 Hrs. Powertrain Control Module Update FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183995 > Dec > 95 > PCM - Ticking Noise from Engine Compartment PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Ticking Noise from Engine Compartment NO: 18-39-95 GROUP: Vehicle Performance DATE: Dec. 8, 1995 SUBJECT: "Ticking" Noise from Engine Compartment MODELS: 1995 (PL) Neon NOTE: This bulletin does not apply to vehicles that have had the Powertrain Control Module reprogrammed on TSB 18-36-95,18-20-95 Rev. A, or 18-38-95 dated December 08, 1995. SYMPTOM/CONDITION: Customer complaint of a "ticking" noise at idle from engine compartment. Condition is more noticeable in cold ambient under 40°F. DIAGNOSIS: Disconnect the electrical connector from the Duty Cycle Evap Purge Solenoid, located over the right front engine mount. If the noise goes away, proceed to the Repair Procedure. If a "ticking" noise is still evident, further diagnosis and repair will be necessary which will not be covered in the bulletin. Before continuing, Diagnostic Trouble Code (DTC) "EVAP PURGE SOLENOID CIRCUIT" will have been set and will have to be erased from memory. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System is required to perform the following repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) which disables the Duty Cycle Evap Purge Solenoid at idle when the ambient temperature is less than 0°F, and delays solenoid operation at idle for 30 minutes when the ambient temperature is between 0°F. and 40°F. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 183995 > Dec > 95 > PCM - Ticking Noise from Engine Compartment > Page 5840 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-93 ......................................................................................................................................... .............................. 0.5 Hrs. Powertrain Control Module Update FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180395 > Feb > 95 > PCM - MIL ON/IAC DTC Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/IAC DTC Set NO: 18-03-95 GROUP: Vehicle Performance EFFECTIVE DATE: Feb. 3, 1995 SUBJECT: Check Engine Light On "Vacuum Leak Found (IAC Fully Seated)" MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC ENGINE AND AUTOMATIC TRANSAXLE. SYMPTOM/CONDITION: Check Engine Light is on, Diagnostic Trouble Code "Vacuum Leak Found (IAC Fully Seated)". DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than "Vacuum Leak Found (IAC Fully Seated)" are present, record them on the repair order for future reference and repair as necessary. NOTE: THE IAC WILL BE FULLY SEATED ONLY WITH A GROSS VACUUM LEAK. THE DIAGNOSTIC ROUTINE IN THE PCM DOES NOT USE IAC DATA IN SETTING THIS FAULT. IF THE IAC CONTROLS THE IDLE SPEED PROPERLY, DO NOT REPLACE IT. Verify that a gross vacuum leak does not exist. With the engine at normal operating temperatures, transmission selector in neutral, using MDS and/or DRBIII, the idle speed should not exceed the target value by more than 50 RPM for more than 10 seconds. If the idle speed is within this limit and only the "Vacuum Leak Found (IAC fully Seated)" DTC is present, proceed with the following repair. EQUIPMENT1PARTS REQUIRED: 1 CH6OOO Scan Tool (DRBIII ) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, then the DTC "Vacuum Leak Found (IAC Fully Seated)" actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180395 > Feb > 95 > PCM - MIL ON/IAC DTC Set > Page 5845 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182694A > Dec > 94 > PCM- Check Engine Light ON/Flash Code 31 PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM- Check Engine Light ON/Flash Code 31 NO: 18-26-94 Rev. A GROUP: Vehicle Performance DATE: Dec. 23, 1994 SUBJECT: Check Engine Light On "Evap Purge Flow Monitor Failure" - Flash Code 31 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-26-94 DATED DEC. 9, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE MODEL APPLICATION NOTE HAS BEEN REVISED. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR AFTER AUG. 6, 1994 (MDH 08-06-XX) THROUGH NOV. 23, 1994 (MDH 11-23-XX), **AND ALSO APPLIES TO ANY VEHICLE WHERE THE PCM WAS REPLACED USING SERVICE BULLETINS 18-18-94 OR 18-25-94.** SYMPTOM/CONDITION: Check Engine Light on, Diagnostic Trouble Code "Evap Purge Flow Monitor Failure" and/or Flash Code 31 is set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than 31 are present, record them on the repair order for future reference and repair as necessary. Verify that the Purge System is functioning properly. Disconnect the purge solenoid hose at the canister. The line should be free of carbon pellets (a light amount of dust is normal). Start the engine. After about 90 seconds, the Duty Cycle Purge Valve should start to cycle. At the open end of the hose one should feel a steady stream of brief vacuum pulses in response to the pulsing of the valve. This is normal and the purge system is functioning properly. If no other codes other than 31 are present, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves reprogramming the powertrain control module with new software. NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATING WITH RELEASE 15 OR HIGHER INSTALLED. This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182694A > Dec > 94 > PCM- Check Engine Light ON/Flash Code 31 > Page 5850 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Steering Column Shake at Idle NO: 18-25-94 GROUP: Vehicle Performance EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Improved Idle Quality on Cold Start Up MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO OCT. 10, 1994 (MDH 10-10-XX). SYMPTOM/CONDITION: Cold start up steering column shake at idle. Condition most noticeable around ambient temperatures of 40 degrees fahrenheit or below. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. EQUIPMENT/PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS BULLETIN INVOLVES REPROGRAMMING PCM'S ON VEHICLES BUILT ON OR AFTER AUGUST 6, 1994, OR REPLACING PCM'S ON VEHICLES BUILT PRIOR TO AUGUST 5, 1994. VEHICLES BUILT PRIOR TO AUGUST 5, 1994: This repair involves replacing the Powertrain Control Module with a new one that incorporates revised software. NOTE: VEHICLES BUILT PRIOR TO APRIL 6, 1994 MAY NOT BE EQUIPPED WITH A STEERING COLUMN DAMPER. TECHNICAL SERVICE BULLETIN 18-07-94 REV. A, DATED JUL. 22, 1994, PROVIDED THE PROCEDURE TO INSTALL A DAMPER WEIGHT, COOLING MODULE BUSHINGS, AND A SOFTWARE CHANGE TO THE PCM TO IMPROVE IDLE ROUGHNESS. ON THOSE VEHICLES BUILT PRIOR TO APRIL 6, 1994 (MDH 04-06-XX), VERIFY THAT TSB 18-07-94 REV. A WAS APPLIED PRIOR TO PROCEEDING WITH THE REPAIR LISTED IN THIS SERVICE BULLETIN. 1. Remove the PCM as outlined on Page 8D - 1 in the 1995 Neon Service Manual Supplement (Publication No. 81-270-5025A), and replace it with the appropriate unit called out in "PARTS REQUIRED". NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle > Page 5855 2. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. VEHICLES BUILT AFTER AUGUST 6, 1994: NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATING WITH RELEASE 15 OR HIGHER INSTALLED. This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182594 > Dec > 94 > PCM - Steering Column Shake at Idle > Page 5856 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-92 Powertrain Control Module - Flash 0.5 Hrs. Failure Code: FM - Flash Module Labor Operation NO: 08-19-02-96 Powertrain Control Module - Replace 0.4 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Idle Roughness/Steering Wheel Shake NO: 18-07-94 Rev. A GROUP: Vehicle Performance DATE: Jul. 22, 1994 SUBJECT: Idle Roughness Accompanied by Steering Wheel Shake THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-94 DATED APR. 29, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN REVISES STEP 15 AND 20. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** . MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 6, 1994 (MDH 04-06-XX). SYMPTOM/CONDITION: Rough running engine during idle accompanied by steering wheel shake. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, repair as necessary, and also perform the following repair. If no codes are present and all systems are functioning correctly, perform the following repair. EQUIPMENT/PARTS REQUIRED: NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the powertrain control module with new software (calibrations), installing a steering wheel damper, replacing the steering wheel clockspring, and, on air conditioning equipped cars, replacing the cooling module lower mounting bushings. 1. Place the front road wheels in the straight ahead position. Rotate the steering wheel one half turn (180 degrees) to the right (clockwise). Lock the column with the ignition lock cylinder. WARNING: BEFORE BEGINNING ANY AIR BAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE, DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THIS WILL DISABLE THE AIR BAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIR BAG COMPONENTS. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the reserve capacitor to discharge. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5861 3. Speed Control Equipped - Remove the two attaching screws for each speed control switch and disconnect the two way electrical connectors. Remove the speed control switches. Non-Speed Control Equipped - Remove the two attaching screws for each pod cover and remove the covers. 4. Remove the 4 screws attaching the steering column cover to the lower instrument panel and remove the trim panel. 5. Remove the 3 screws attaching the steering column cover liner and remove from the lower instrument panel. 6. Remove the 2 air bag module attaching screws from under the steering wheel. WARNING: WHEN HANDLING AN UNDEPLOYED AIR BAG MODULE DURING SERVICING OF THE STEERING COLUMN, THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED. AT NO TIME SHOULD A SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF THE AIR BAG MODULE. WHEN CARRYING A LIVE MODULE, THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF THE MODULE ACCIDENTALLY DEPLOYS. IF AN AIR BAG MODULE IS PLACED ON A BENCH OR OTHER SURFACE, THE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT. 7. Lift the air bag module and disconnect the clockspring electrical lead from the back of the module. Remove the air bag module. 8. Disconnect the clockspring electrical lead from the steering wheel horn switches and wiring harness. 9. Remove the steering wheel retainer nut from the steering column shaft. 10. Remove the steering wheel assembly from column shaft using Puller, Special tool C-3428-B. CAUTION: WHEN INSTALLING PULLER C3428-B, BE SURE BOLTS ARE FULLY SEATED IN THE THREADED PULLER HOLES ON THE STEERING WHEEL. DO NOT BUMP OR HAMMER ON THE STEERING WHEEL OR STEERING COLUMN SHAFT WHEN REMOVING WHEEL FROM THE STEERING COLUMN. 11. Lift up the instrument cluster top cover and the cluster bezel until the clips disengage and separate. 12. Insert a screw driver into the access hole at the lower shroud and depress the cylinder button while rotating the cylinder with the key inserted between the ON and START positions to disengage the cylinder from the column. 13. Pull the key cylinder out. 14. Remove the three lower to upper shroud attaching screws through the bottom of the lower shroud. Separate the upper and lower shrouds. 15. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness and at the base of the clockspring. 16. Unlatch and remove the clockspring assembly from the steering shaft. Discard the clockspring. "NOTE: WHEN INSTALLING A NEW CLOCKSPRING, MAKE SURE THE FRONT WHEELS ARE NOT MOVED.** 17. Install new clockspring. Remove the "T" pin from the clockspring and rotate the clock spring rotor one half turn (180 degrees) to the right (clockwise). Connect the clockspring to the instrument panel harness and ensure that the wiring is properly routed. Check the wiring connectors and locking tabs to make sure they are properly engaged. 18. Install the steering wheel ensuring the flats on the hub align with the clockspring. Pull the horn lead, air bag and speed control leads through the larger slot. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5862 19. Position the new damper weight as shown in Figure 1, and install the steering column shaft retaining nut and tighten until steering wheel is fully seated on the shaft. Torque the steering wheel retaining nut to 54 N-m (40 ft.lbs.). 20. Connect the clockspring lead to the horn switches. Route speed control leads (one to each speed control opening). 21. Install the air bag electrical lead from the clockspring into the connector on the back of the air bag module. NOTE: ** BE SURE CONNECTOR IS SECURELY LATCHED INTO THE AIR BAG MODULE CONNECTOR AND THAT THE WIRE IS ORIENTED TOWARD THE BOTTOM OF THE AIR BAG.** 22. Continue installation of the components that were removed to gain access to the clockspring. Make sure original or correct attaching bolts are used. 23. Refer to the Air Bag System Check listed in the Neon Service Manual (Publication No. 81-270-5025) Page SM-4, to verify that Air Bag is installed and operating properly. NOTE: STEPS 23 THROUGH 26 ARE REQUIRED ONLY ON VEHICLES EQUIPPED WITH AIR CONDITIONING. 24. Remove the 2 upper radiator isolator bracket mounting screws. Loosen the radiator to battery strut attaching screw. 25. Raise the cooling module high enough to free the 2 lower mounting isolator bushings from the front crossmember and support the cooling module in this position. 26. Replace the 2 lower mounting isolator bushings with new bushings. 27. Install the cooling module into the lower mounting brackets. Install and tighten the 2 upper radiator isolator bracket mounting screws to 7.4 N-m (65 in.lbs.). NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING STEPS AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. 28. Connect the Mopar Diagnostic System (MDS) and DRBIII Scan Tool to the vehicle and power them up. 29. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 30. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 31. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 32. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180794A > Jul > 94 > PCM - Idle Roughness/Steering Wheel Shake > Page 5863 33. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 34. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the controller on the vehicle cannot be programmed or has already been programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 36. 35. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 36. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover label with a clear plastic sticker. 37. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-95 1.2 Hrs. FAILURE CODE: FC - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 140694B > May > 94 > MIL ON, O2 Sensor DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins MIL ON, O2 Sensor DTC's Set NO: 14-06-94 Rev. B GROUP: Fuel DATE: May 20, 1994 SUBJECT: Check Engine Light On, Code 21, Up or Downstream 02S Shorted to Voltage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-06-94 REV. A, DATED MAY 6, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN PROVIDES FOR REPROGRAMMING THE POWERTRAIN CONTROL MODULE RATHER THAN REPLACING THE MODULE. THE LABOR OPERATION NO. AND TIME HAVE BEEN REVISED TO REFLECT THIS CHANGE, AND INCORRECT OHS REFERENCES ARE CHANGED TO 02S. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 5, 1994 (MDH 04-05-XX). SYMPTOM/CONDITION: The "Check Engine" light illuminates with flash code # 21, or Diagnostic Trouble Code "Upstream 02S Shorted To Voltage or Downstream 02S Shorted To Voltage" is set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference. If codes other than "Upstream or Downstream 02S Shorted to Voltage" are present, repair as necessary. If the "Upstream or Downstream 02S Shorted To Voltage" is present and all other systems are functioning correctly, proceed with the following repair. **EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 13 OR HIGHER. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the powertrain control module with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller. 7. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 140694B > May > 94 > MIL ON, O2 Sensor DTC's Set > Page 5868 If the controller on the vehicle cannot be programmed or has already been programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9. 8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process. If the condition is still present after reprogramming the Powertrain Control Module, follow the diagnostic procedure for either "Upstream or Downstream 02S Shorted to Voltage" and repair as necessary. NOTE: DO NOT INSTALL ANY GREASE IN THE OXYGEN SENSOR CONNECTOR OR USE ANY SILICONE PRODUCT ON OR NEAR THE OXYGEN SENSOR. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker." 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-96 0.4 Hrs. FAILURE CODE: FC - Flash Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5874 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5875 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5876 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5877 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5878 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5879 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5880 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5881 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5882 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5883 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5884 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5885 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5886 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5887 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5888 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5889 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5890 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5891 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5892 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 5901 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5902 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5903 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 5911 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5912 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5913 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown Band: Specifications Kickdown band adjustment 45 - 50 in.lb Then back off 2 1/2 turns. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown > Page 5918 Band: Specifications Low/Reverse band adjustment 41 in.lb Then back off 3 1/2 turns. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 5919 Band: Adjustments KICKDOWN BAND (FRONT) The kickdown band adjusting screw is located on left side (top front) of the transaxle case. 1. Loosen locknut and back-off nut approximately five turns. Test adjusting screw for free turning in the transaxle case. 2. Using wrench, tighten adjusting screw to 8 Nm (72 inch lbs.). 3. Back-off adjusting screw 2 1/4 turns. Hold adjusting screw in this position and tighten locknut to 47 Nm (35 ft. lbs.) LOW/REVERSE BAND (REAR) To adjust low/reverse band, proceed as follows: 1. Loosen and back off locknut approximately five turns. 2. Using an inch-pound torque wrench, tighten adjusting screw to 5 Nm (41 inch lbs.) true torque. 3. Back-off adjusting screw 3 1/2 turns. 4. Tighten locknut to 14 Nm (10 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Clutch Clearance and Selective Snap Rings: Front Clutch (Non-Adjustable) Measured from Reaction Plate to "Farthest" Wave 3 Disk ................................................................................................................................................... .............. 2.22 - 3.37 mm (0.087 - 0.133 inch) 4 Disk .......................................................................... ....................................................................................... 2.29 - 3.71 mm (0.090 - 0.146 inch) Rear Clutch (3 and 4 Disc, Adjustable) 3 Disc ................................................................................................................................................... ............... 0.67 - 1.10 mm (0.026 - 0.043 mm) 4 Disc .......................................................................... ........................................................................................ 0.67 - 1.10 mm (0.026 - 0.043 mm) Selective Snap Rings (5) Size 1 ................................................................................................................................................... ................ 1.22 - 1.27 mm (0.048 - 0.050 inch) Size 2 ........................................................................ ........................................................................................... 1.52 - 1.57 mm (0.060 - 0.062 inch) Size 3 ........................................................................................................................................................... ........ 1.73 - 1.78 mm (0.068 - 0.070 inch) Size 4 ................................................................................ ................................................................................... 1.88 - 1.93 mm (0.074 - 0.076 inch) Size 5 ..... .............................................................................................................................................................. 2.21 - 2.26 mm (0.087 - 0.089 inch) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 5923 Measuring Rear Clutch Plate Clearance Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Service and Repair Differential Transfer Shaft: Service and Repair 1. Remove rear cover attaching bolts and rear cover. Fig. 5 Transfer Shaft Gear Nut Removal 2. Using transfer shaft gear tool No. L-4434, or equivalent, remove transfer shaft gear retaining nut, Fig.5. Fig. 6 Transfer Shaft Gear Removal 3. Using transfer shaft gear puller tool No. L-4407, or equivalent, remove transfer shaft gear and shim, Fig.6. 4. Remove governor support retainer, then remove low-reverse band anchor pin. 5. Remove governor assembly. 6. Remove transfer shaft retainer snap ring, then using transfer shaft and bearing retainer removal tool No. L-4512, or equivalent and a suitable puller, remove transfer shaft and retainer assembly. 7. Remove transfer shaft retainer from shaft. 8. Using a screwdriver, remove oil seal from transfer shaft retainer. 9. Using suitable tool, tap oil seal into shaft retainer. 10. Reverse procedure to install. Torque transfer shaft gear retaining nut to 200 ft. lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 5935 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 5936 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 5937 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 5938 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 5939 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transaxle/Transmission - Automatic CAPACITY Estimated service refill ......................................................................................................................... .................................................. 3.8 l (4.0 qts) Overhaul refill with torque converter ...................................................................................................................................................... 8.2 l (8.8 qts) TYPE ................................................................................................................................................... ................................................. MOPAR ATF+4 [1] [1] Or Dexron II. Initial Refill Capacity CAPACITY Estimated service refill ......................................................................................................................... .................................................. 3.8 l (4.0 qts) Overhaul refill with torque converter ...................................................................................................................................................... 8.2 l (8.8 qts) TYPE ................................................................................................................................................... ................................................. MOPAR ATF+4 [1] [1] Or Dexron II. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5942 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Whenever the factory fill fluid is changed, only fluids of the type labeled MOPAR ATF+4 (Type 9602) should be used. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair Governor: Service and Repair The governor assembly can be removed for reconditioning or replacement without removing the transfer gear cover, transfer gear and governor support. To remove governor, drain transmission fluid and remove transmission oil pan. Remove valve body, unbolt governor from governor support, then remove governor. When cleaning or assembling the governor assembly, ensure governor valves move freely in governor body bores. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation > Page 5954 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5977 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments Shift Interlock Cable: Adjustments 1. Disconnect battery ground cable, then remove console assembly. 2. Remove gearshift knob set screw and knob. 3. Remove gearshift indicator bezel and indicator lamp, then install gearshift knob. 4. Place shifter in Park position. 5. Place ignition in Lock or Accessory position. If cable is out of adjustment, then grasp slug on interlock cable with a suitable pair of pliers and pull back on cable. This will allow ignition to be placed in position. 6. Ensure interlock cable is completely seated into shifter interlock lever, then ensure ignition is in Lock or Accessory position. 7. Pry up adjuster lock on interlock cable. Spring on interlock cable should automatically adjust for slack in cable. 8. Snap interlock cable adjuster lock onto cable. 9. Remove gearshift knob set screw and knob. 10. Install indicator lamp, gearshift bezel and gearshift knob. 11. Connect battery ground cable. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 5984 Shift Interlock Cable: Service and Repair 1. Disconnect battery ground cable, then remove console assembly. 2. Remove gearshift knob set screw and knob. 3. Remove gearshift bezel and indicator lamp. 4. Pry up adjuster lock on interlock cable. 5. Pull cable up and out of gearshift assembly. 6. Remove lower steering column cover and liner. 7. Lift top cover and cluster bezel until clips disengage to provide clearance. 8. Place ignition in On position. 9. Insert a screwdriver into access hole in lower shroud and depress cylinder button while rotating cylinder to disengage it from column. 10. Remove upper and lower shrouds. 11. Disconnect interlock cable from interlock assembly, then remove interlock cable. 12. Reverse procedure to install. Adjust interlock cable as described under Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211294 > Jun > 94 > A/T Gearshift Lever - Buzz Noise on Rough Roads Shifter A/T: Customer Interest A/T Gearshift Lever - Buzz Noise on Rough Roads NO: 21-12-94 GROUP: Transmission DATE: Jun. 6, 1994 SUBJECT: Automatic Transmission Gearshift Lever Buzz MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Buzzing sound coming from the gearshift lever/knob while driving on gravel roads, uneven pavement (tar strips), or washboard surfaces. DIAGNOSIS: Verify the condition by driving the vehicle on the same or similar road surfaces. PARTS REQUIRED: 1 83506385 Gearshift Lever Grease REPAIR PROCEDURE: This bulletin involves removing the gearshift knob and liberally applying grease to the gearshift lever. 1. Loosen the gearshift lever knob set screw and remove the knob from the lever. 2. Liberally apply approximately 1/2 teaspoon (1 oz.) of Gearshift Lever Grease into the end of the shift lever tube. The grease should fill the space between the shift rod and the tube. 3. Install the gearshift knob making sure that it is fully seated and tightened the knob set screw. To prevent stripping the knob set screw do not exceed 20 in. lbs. 4. Verify that the gearshift assembly is properly functioning. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-75-13-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211294 > Jun > 94 > A/T Gearshift Lever Buzz Noise on Rough Roads Shifter A/T: All Technical Service Bulletins A/T Gearshift Lever - Buzz Noise on Rough Roads NO: 21-12-94 GROUP: Transmission DATE: Jun. 6, 1994 SUBJECT: Automatic Transmission Gearshift Lever Buzz MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Buzzing sound coming from the gearshift lever/knob while driving on gravel roads, uneven pavement (tar strips), or washboard surfaces. DIAGNOSIS: Verify the condition by driving the vehicle on the same or similar road surfaces. PARTS REQUIRED: 1 83506385 Gearshift Lever Grease REPAIR PROCEDURE: This bulletin involves removing the gearshift knob and liberally applying grease to the gearshift lever. 1. Loosen the gearshift lever knob set screw and remove the knob from the lever. 2. Liberally apply approximately 1/2 teaspoon (1 oz.) of Gearshift Lever Grease into the end of the shift lever tube. The grease should fill the space between the shift rod and the tube. 3. Install the gearshift knob making sure that it is fully seated and tightened the knob set screw. To prevent stripping the knob set screw do not exceed 20 in. lbs. 4. Verify that the gearshift assembly is properly functioning. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-75-13-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises Clutch Release Fork: All Technical Service Bulletins Clutch Pedal - Squeak/Creak/Chirp Noises NO: 06-02-94 GROUP: Clutch EFFECTIVE DATE: Sep. 2, 1994 SUBJECT: Noise When Operating Clutch Pedal MODELS: 1995 (PL) Neon (FJ) Talon (Non Turbo Equipped) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE. SYMPTOM/CONDITION: There are two possible noise sources that may be encountered while operating the clutch pedal. 1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature. 2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures. DIAGNOSIS: CONDITION 1: Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever. CONDITION 2 - Neon Only Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release. Perform the appropriate repair for the specific condition encountered. PARTS REQUIRED: (Condition 1) 1 4796664 Throwout Lever and Pivot Package 1995 Neon 1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo AR 4318063 Mopar Multi-Purpose Grease AR 4318031 Mopar Lock N' Seal PARTS REQUIRED: (Condition 2 - Neon Only) 1 4670400 Cable Assembly - Clutch Release TOOLS REQUIRED: (Condition 1) Slide Hammer Miller Tool # C-3752 Pivot Remover/Installer Tool Miller Tool # 6891 REPAIR PROCEDURE: (Condition 1) This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot. 1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6003 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6004 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6005 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6011 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6012 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6013 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments 1. Set parking brake, then remove floor console. 2. Place gear selector lever in (P) park position, then unsnap collar at shifter cable. 3. Move gear selector lever on transaxle to park position, then verify that both shifter lever and transaxle are in park position. 4. Rotate collar on shift cable adjuster until it seats against plastic housing, Fig.4. Collar must seat against plastic housing to achieve required detent lock position. 5. Inspect adjustment as follows: a. Detent position for neutral and drive should be within limits of hand lever gate stops. b. Key start must occur only when shift lever is in neutral or park positions. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, A/T: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, A/T: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, A/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6026 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, A/T: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6032 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Throttle Valve Cable/Linkage: Customer Interest A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6041 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6042 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6043 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211394 > Aug > 94 > A/T - Harsh or Erratic Shifts Throttle Valve Cable/Linkage: Customer Interest A/T - Harsh or Erratic Shifts NO: 21-13-94 GROUP: Transmission DATE: Aug. 5, 1994 SUBJECT: Automatic Transmission Harsh or Erratic Shifts MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Erratic, late, or harsh automatic transmission shifts. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following: 1. Road test the vehicle by slowly accelerating to 18 to 20 miles per hour and maintain vehicle speed for 2 to 3 seconds. 2. Check the engine RPM'S. If the RPM's are 1800 or less, then an upshift has occurred and the erratic shift condition must be diagnosed following the Diagnostic Chart shown on Page 21-36 of the Neon Service Manual (Publication No. 81-270-5025). If the engine speed is greater than 1800 RPM'S, the transmission shift point is improper. This indicates that the transmission throttle pressure kick-down cable may be out of adjustment. Proceed to the repair listed in this bulletin. PARTS REQUIRED: No parts are required for this repair. REPAIR PROCEDURE: This bulletin involves adjusting the transmission throttle pressure kick-down cable. NOTE: THE VEHICLE ENGINE MUST BE AT NORMAL OPERATING TEMPERATURES TO PROPERLY PERFORM THIS PROCEDURE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211394 > Aug > 94 > A/T - Harsh or Erratic Shifts > Page 6048 1. Release the cable adjuster lock (cross-lock) on the throttle pressure cable assembly. NOTE: TO ENSURE PROPER ADJUSTMENT, THE CABLE MUST BE FREE TO SLIDE ALL THE WAY TOWARD THE ENGINE, AGAINST ITS STOP, AFTER THE CROSS-LOCK IS RELEASED. 2. Move the transaxle throttle control lever fully clockwise, against its internal stop, and press the cross-lock downward into the locked position. This completes the adjustment. 3. Test cable freedom of operation by moving the transaxle throttle lever forward (counterclockwise). Then slowly release it to confirm it will return fully rearward (clockwise). NOTE: NO LUBRICATION IS REQUIRED FOR ANY COMPONENT OF THE THROTTLE CABLE SYSTEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-75-32-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Throttle Valve Cable/Linkage: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6054 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6055 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6056 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211394 > Aug > 94 > A/T - Harsh or Erratic Shifts Throttle Valve Cable/Linkage: All Technical Service Bulletins A/T - Harsh or Erratic Shifts NO: 21-13-94 GROUP: Transmission DATE: Aug. 5, 1994 SUBJECT: Automatic Transmission Harsh or Erratic Shifts MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Erratic, late, or harsh automatic transmission shifts. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following: 1. Road test the vehicle by slowly accelerating to 18 to 20 miles per hour and maintain vehicle speed for 2 to 3 seconds. 2. Check the engine RPM'S. If the RPM's are 1800 or less, then an upshift has occurred and the erratic shift condition must be diagnosed following the Diagnostic Chart shown on Page 21-36 of the Neon Service Manual (Publication No. 81-270-5025). If the engine speed is greater than 1800 RPM'S, the transmission shift point is improper. This indicates that the transmission throttle pressure kick-down cable may be out of adjustment. Proceed to the repair listed in this bulletin. PARTS REQUIRED: No parts are required for this repair. REPAIR PROCEDURE: This bulletin involves adjusting the transmission throttle pressure kick-down cable. NOTE: THE VEHICLE ENGINE MUST BE AT NORMAL OPERATING TEMPERATURES TO PROPERLY PERFORM THIS PROCEDURE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211394 > Aug > 94 > A/T - Harsh or Erratic Shifts > Page 6061 1. Release the cable adjuster lock (cross-lock) on the throttle pressure cable assembly. NOTE: TO ENSURE PROPER ADJUSTMENT, THE CABLE MUST BE FREE TO SLIDE ALL THE WAY TOWARD THE ENGINE, AGAINST ITS STOP, AFTER THE CROSS-LOCK IS RELEASED. 2. Move the transaxle throttle control lever fully clockwise, against its internal stop, and press the cross-lock downward into the locked position. This completes the adjustment. 3. Test cable freedom of operation by moving the transaxle throttle lever forward (counterclockwise). Then slowly release it to confirm it will return fully rearward (clockwise). NOTE: NO LUBRICATION IS REQUIRED FOR ANY COMPONENT OF THE THROTTLE CABLE SYSTEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-75-32-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6067 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6068 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6069 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 6074 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6080 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6081 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 6082 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Cable/Linkage: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 6087 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 6088 Throttle Valve Cable/Linkage: Adjustments CABLE TYPE 1. Perform adjustment with engine at operating temperature. 2. Loosen cable mounting bracket lock screw. 3. Position mounting bracket with both alignment tabs touching transaxle cast surface. 4. Release cross-lock on cable assembly by pulling the cross-lock upward. To ensure proper adjustment, the cable must be free to slide all the way toward engine, against its stop, after the cross-lock is released. 5. Move transaxle throttle control lever fully clockwise against its internal stop, and press cross-lock downward into locked position. 6. Check cable for freedom of movement by moving throttle control lever. ROD TYPE 1. Ensure engine is at operating temperature. 2. Loosen adjustment swivel lock screw. Swivel must slide freely along flat end of throttle rod. 3. Hold transaxle throttle lever firmly toward engine, against its internal stop. Torque swivel lock screw to 8 Ft. lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 6094 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6095 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6096 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6118 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 31TH Transmission Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift Valve Body: Customer Interest A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 6132 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 6133 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 6134 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Valve Body: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6140 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6141 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 6142 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection Valve Body: Service and Repair Cleaning and Inspection CLEANING AND INSPECTION 1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions. 2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. 3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen light, inspect bores in valve body for scores scratches, pits and irregularities. 4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. 5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling. 6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill transaxle to the proper level with ATF. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6145 Valve Body: Service and Repair Overhaul VALVE BODY RECONDITION NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only R.T.V. sealant when installing oil pan. Oil Pan Bolts Oil Pan 1. Remove or install neutral starting and back-up lamp switch. Oil Filter Screws Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6146 Oil Filter Parking Rod E-Clip Parking Rod Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6147 Valve Body Attaching Bolts Valve Body And Governor Tubes CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. Detent Spring Attaching Screw And Spring WARNING: Tag all springs as they are removed for reassembly identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6148 Valve Body Screws Valve Body Screws Transfer Plate And Separator Plate Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6149 Steel Ball Locations Throttle Shaft E-Clip E-Clip, Washer And Oil Seal Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6150 Manual Valve Lever And Assembly Throttle Valve Lever And Assembly Manual Valve Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6151 Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6152 Governor Plugs Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 6153 Shift And Shuttle Valve Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Customer Interest for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises Clutch Cable: Customer Interest Clutch Pedal - Squeak/Creak/Chirp Noises NO: 06-02-94 GROUP: Clutch EFFECTIVE DATE: Sep. 2, 1994 SUBJECT: Noise When Operating Clutch Pedal MODELS: 1995 (PL) Neon (FJ) Talon (Non Turbo Equipped) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE. SYMPTOM/CONDITION: There are two possible noise sources that may be encountered while operating the clutch pedal. 1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature. 2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures. DIAGNOSIS: CONDITION 1: Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever. CONDITION 2 - Neon Only Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release. Perform the appropriate repair for the specific condition encountered. PARTS REQUIRED: (Condition 1) 1 4796664 Throwout Lever and Pivot Package 1995 Neon 1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo AR 4318063 Mopar Multi-Purpose Grease AR 4318031 Mopar Lock N' Seal PARTS REQUIRED: (Condition 2 - Neon Only) 1 4670400 Cable Assembly - Clutch Release TOOLS REQUIRED: (Condition 1) Slide Hammer Miller Tool # C-3752 Pivot Remover/Installer Tool Miller Tool # 6891 REPAIR PROCEDURE: (Condition 1) This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot. 1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Customer Interest for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6163 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Customer Interest for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6164 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Customer Interest for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6165 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises Clutch Cable: All Technical Service Bulletins Clutch Pedal - Squeak/Creak/Chirp Noises NO: 06-02-94 GROUP: Clutch EFFECTIVE DATE: Sep. 2, 1994 SUBJECT: Noise When Operating Clutch Pedal MODELS: 1995 (PL) Neon (FJ) Talon (Non Turbo Equipped) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE. SYMPTOM/CONDITION: There are two possible noise sources that may be encountered while operating the clutch pedal. 1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature. 2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures. DIAGNOSIS: CONDITION 1: Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever. CONDITION 2 - Neon Only Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release. Perform the appropriate repair for the specific condition encountered. PARTS REQUIRED: (Condition 1) 1 4796664 Throwout Lever and Pivot Package 1995 Neon 1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo AR 4318063 Mopar Multi-Purpose Grease AR 4318031 Mopar Lock N' Seal PARTS REQUIRED: (Condition 2 - Neon Only) 1 4670400 Cable Assembly - Clutch Release TOOLS REQUIRED: (Condition 1) Slide Hammer Miller Tool # C-3752 Pivot Remover/Installer Tool Miller Tool # 6891 REPAIR PROCEDURE: (Condition 1) This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot. 1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6171 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6172 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Cable: > 060294 > Sep > 94 > Clutch Pedal Squeak/Creak/Chirp Noises > Page 6173 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Page 6174 Clutch Cable: Adjustments The clutch cable used on these vehicles incorporates a self adjusting mechanism within the cable outer housing at the pedal end of the cable. A preload spring is used to take up slack in the cable and to keep the release bearing tensional against the fingers of the clutch pressure plate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Page 6175 Clutch Cable: Service and Repair CLUTCH CABLE The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. REMOVAL 1. Pull up and remove Power Distribution Center. 2. Remove transaxle splash cover. 3. Pun back on clutch cable housing and disengage cable from housing. 4. Guide cable through slot in transaxle and disconnect cable from release lever. 5. Disconnect clutch cable from clutch pedal up- stop/spacer Note: Depressing the clutch pedal provides access to the clutch cable strand. Disconnect the cable end from the spacer by inserting a hooked tool into the clearance hole on the inboard side of the up-upstop/spacer. Now push the cable out- ward. Remove the upstop/spacer by inserting a screwdriver between the spacer and the shoulder of the pin on the clutch pedal. CAUTION: Do not pull on the clutch cable housing to move It from the dash panel. Damage to the cable if adjuster may occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Technical Service Bulletins > Page 6176 6. Cable End Removal:Use a slight twisting motion while grasping the grommet and body to remove the cable from the dash panel and clutch bracket. a screwdriver may be required to dislodge the cable grommet from the dash panel. Use caution to avoid damage to the cable grommet. INSTALLATION: 1. Using a slight twisting motion, insert the self adjuster mechanism end of the clutch cable through the dash panel hole and into the bracket 2. Seat the 8mm wide groove on the cable grommet in the dash panel. Make sure the self adjuster is firmly seated against the clutch bracket to ensure proper adjuster mechanism function. 3. Connect the clutch cable to the up-step/spacer. 4. Connect the up-stop/spacer to the clutch pedal. 5. Adjuster mechanism function check: With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel (With less than 15 lbs. of effort the cable housing should move 30-50mm). This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. 6. If the adjust mechanism functions properly, guide the cable through the slot in the transaxle housing. Connect cable to release lever, seating the cupped washer securely on lever tangs. 7. Pull back on clutch cable housing and insert into transaxle housing. 8. Reinstall splash cover and Power Distribution Center. Check clutch pedal position switch operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Clutch Pedal - Up Stop/Spacer Installation Clutch Pedal Assembly: Technical Service Bulletins Clutch Pedal - Up Stop/Spacer Installation NO.: 06-04-94 GROUP: Clutch DATE: Oct. 7, 1994 SUBJECT: Clutch Up Stop/Spacer Installation MODELS: 1995 (PL) Neon DISCUSSION: The installation procedure for the clutch up stop/spacer has been changed to provide for a more positive engagement onto the clutch pedal pin. The illustration provides the details for the new installation procedure. When replacing the up stop/spacer for any reason, use this installation procedure and the new parts replacement package listed in Parts Required. Note: The clutch cable adjustment procedure remains the same as before. PARTS REQUIRED: 1 4796913 Package - Clutch Up Stop/Spacer POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises Clutch Release Fork: Customer Interest Clutch Pedal - Squeak/Creak/Chirp Noises NO: 06-02-94 GROUP: Clutch EFFECTIVE DATE: Sep. 2, 1994 SUBJECT: Noise When Operating Clutch Pedal MODELS: 1995 (PL) Neon (FJ) Talon (Non Turbo Equipped) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE. SYMPTOM/CONDITION: There are two possible noise sources that may be encountered while operating the clutch pedal. 1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature. 2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures. DIAGNOSIS: CONDITION 1: Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever. CONDITION 2 - Neon Only Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release. Perform the appropriate repair for the specific condition encountered. PARTS REQUIRED: (Condition 1) 1 4796664 Throwout Lever and Pivot Package 1995 Neon 1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo AR 4318063 Mopar Multi-Purpose Grease AR 4318031 Mopar Lock N' Seal PARTS REQUIRED: (Condition 2 - Neon Only) 1 4670400 Cable Assembly - Clutch Release TOOLS REQUIRED: (Condition 1) Slide Hammer Miller Tool # C-3752 Pivot Remover/Installer Tool Miller Tool # 6891 REPAIR PROCEDURE: (Condition 1) This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot. 1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6192 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6193 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6194 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises Clutch Release Fork: All Technical Service Bulletins Clutch Pedal - Squeak/Creak/Chirp Noises NO: 06-02-94 GROUP: Clutch EFFECTIVE DATE: Sep. 2, 1994 SUBJECT: Noise When Operating Clutch Pedal MODELS: 1995 (PL) Neon (FJ) Talon (Non Turbo Equipped) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSAXLE. SYMPTOM/CONDITION: There are two possible noise sources that may be encountered while operating the clutch pedal. 1. Squeak/creak sound heard when the clutch pedal is about half way through full pedal application or travel. This sound can be heard during apply or release of the clutch pedal, and is most noticeable when the vehicle is stationary and is at normal operating temperature. 2. Neon Only - Squeak/chirp sound heard when the clutch pedal is initially engaged or at the top of pedal travel. This sound is not heard on pedal release, and is not sensitive to vehicle operating temperatures. DIAGNOSIS: CONDITION 1: Start with a fully warmed up vehicle. With the engine off, from inside the vehicle, depress the clutch pedal about half way through its full travel and listen for a squeak/creak sound coming from the area of the clutch housing (center of the front floor area under the dash). The sound can be confirmed by raising the hood and listening in the area of the clutch housing throwout lever. CONDITION 2 - Neon Only Depress the clutch pedal through the first 2 inches of travel. The squeak/chirp sound will be heard coming from the top of the clutch pedal pivot under the dash. The sound will only be heard on the pedal application and not on pedal release. Perform the appropriate repair for the specific condition encountered. PARTS REQUIRED: (Condition 1) 1 4796664 Throwout Lever and Pivot Package 1995 Neon 1 4796665 Throwout Lever and Pivot Package 1995 Talon - Non Turbo AR 4318063 Mopar Multi-Purpose Grease AR 4318031 Mopar Lock N' Seal PARTS REQUIRED: (Condition 2 - Neon Only) 1 4670400 Cable Assembly - Clutch Release TOOLS REQUIRED: (Condition 1) Slide Hammer Miller Tool # C-3752 Pivot Remover/Installer Tool Miller Tool # 6891 REPAIR PROCEDURE: (Condition 1) This procedures involves removing the transaxle assembly to replace the clutch throwout lever and pivot. 1. Neon - Following the procedure outlined on Pages 21-7 and 21-8 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove the Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6200 transaxle from the vehicle. Talon - Follow the procedure outlined on Page 21A-99 in the 1995 Talon Service Manual (Publication No. 81-270-5500), remove the transaxle from the vehicle. 2. Simultaneously, remove the clutch throwout lever and throwout bearing to prevent damage to the throwout bearing retaining tabs. Discard the lever. 3. Remove the throwout lever pivot using slide hammer, Miller Tool # C-3752, and pivot remover/installer, Miller Tool # 6891 (Figure 1). Discard the pivot. 4. Install the new pivot using pivot remover/installer, Miller Tool 6891, and slide hammer, Miller Tool C-3572 (Figure 2). NOTE: APPLY A SMALL AMOUNT OF MOPAR LOCK N' SEAL, P/N 4318031, TO THE SERRATION OF THE PIVOT STUD BEFORE INSTALLATION. MAKE SURE THE BASE OF THE PIVOT IS FULLY SEATED AGAINST THE BOSS ON THE BELLHOUSING. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6201 5. Lubricate the areas shown on Figure 3 with Mopar Multi-Purpose Grease, P/N 4318063. 6. Install new throwout lever. The lever must be assembled onto the throwout bearing first and both the bearing and lever are installed on the throwout bearing guide tube and the stud simultaneously (Figure 4). 7. Install transaxle by reversing the removal procedure. Fill transaxle to bottom of fill hole plug with Mopar Manual Transaxle Fluid (MS9417), P/N 4773167. Use of other types of fluids could result in hard shifting or synchronizer failure. 8. Neon - Perform the Gearshift Cable Crossover Adjustment following the procedures outlined in the Neon Service Manual on Page 21-4. Talon - Bleed the Clutch Line following the procedure outlined in the Talon Service Manual on Page 6-6. REPAIR PROCEDURE: (Condition 2 - Neon Only) This procedure involves replacing the Clutch Release Cable Assembly. Following the procedure outlined on page 6-2 and 6-3 in the 1995 Neon Service Manual (Publication No. 81-270-5025), remove and replace the clutch release cable assembly with cable assembly, P/N 4670400. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Condition 1 Labor Operation No: 06-40-10-96 Neon 2.6 Hrs. Talon 2.8 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Fork: > 060294 > Sep > 94 > Clutch Pedal - Squeak/Creak/Chirp Noises > Page 6202 FAILURE CODE: P8 - New Part Condition 2 - Neon Only Labor Operation No. 06-50-15-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash Technical Service Bulletin # 020195 Date: 950127 Front Drive Axle - Vibration in Floor/Dash NO: 02-01-95 GROUP: Front Suspension DATE: Jan. 27, 1995 SUBJECT: Vibration in Floor Pan/Dash Panel 2800 to 4200 RPM Range MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AUTOMATIC TRANSAXLES AND BUILT PRIOR TO OCT. 24, 1994 (MDH 10-24-XX). SYMPTOM/CONDITION: Right side driveshaft vibration coming from the engine compartment and occurring between 2800 and 4200 RPM. The vibration is most noticeable at approximately 3200 RPM and may be felt in the floor pan and/or in the dash panel. DIAGNOSIS: 1. Start the vehicle and place the transmission in neutral or park. Set the parking brake. 2. Slowly depress the accelerator pedal until the engine reaches approximately 4800 RPM. Pay particular attention for any vibration (other than normal engine/exhaust vibrations) starting at around the 2800 RPM and most evident around 3200 RPM, then getting less noticeable and disappearing around 4200 RPM. The vibration may be felt in the floor pan and/or in the dash. 3. If a vibration is felt that starts and disappears at the RPM ranges listed above, perform the repair procedure. If the vibration does not conform to these RPM ranges, follow the vibration diagnostic procedure listed in the 1995 Service Manual. PARTS REQUIRED: 1 4670280 Driveshaft - ATX Without ABS -Rt 1 4670282 Driveshaft - ATX With ABS -Rt 1 6500336 Pin, Cotter Service Procedure REPAIR PROCEDURE: This bulletin involves replacing the right side driveshaft with a revised part. Figures 1-2 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6213 1. Remove the cotter pin, nut lock and spring washer (Refer to Figure 1) from the end of the right driveshaft. CAUTION: DO NOT ROLL THE VEHICLE ON THE GROUND AFTER THE HUB NUT IS LOOSENED. BEARING DAMAGE WILL RESULT. 2. Loosen but do not remove the hub nut while the weight of the vehicle is supported on the right tire/wheel assembly and the brakes are applied. 3. Raise the vehicle on a frame contact type hoist. 4. Remove the right front tire/wheel assembly from the hub. 5. Remove the right front disc brake caliper to steering knuckle attaching bolts (Refer to Figure 2). Figures 3-4 6. Remove the disc brake caliper assembly from the steering knuckle. The caliper is removed by first lifting the bottom of the caliper away from the steering knuckle, then removing the top of the caliper out from under the steering knuckle (Refer to Figure 3). 7. Support the caliper assembly using a wire hook. DO NOT ALLOW THE CALIPER ASSEMBLY TO HANG BY THE BRAKE FLEX HOSE. 8. Remove the brake disc from the front hub. 9. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud with a 11/32 in. socket while loosening the attaching nut (Refer to Figure 4). Figures 5-6 10. Use Special Tool MB 990635 to remove the tie rod end stud from the steering knuckle (Refer to Figure 5). 11. Remove the nut and bolt clamping the ball joint stud into the steering knuckle (Refer to Figure 6). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6214 Figures 7-8 12. Separate the ball joint stud from the steering knuckle by prying down on the lower control arm (Refer to Figure 7). USE CAUTION WHEN SEPARATING THE BALL JOINT FROM THE STEERING KNUCKLE SO THE BALL JOINT SEAL IS NOT DAMAGED. 13. Pull the steering knuckle out/away from the end of the driveshaft (Refer to Figure 8). 14. Support the outer end of the driveshaft. Figures 9-10 15. Remove the driveshaft from the transaxle side gear by placing a brass drift/punch against the inner tripod joint and hitting it sharply to dislodge the snap ring (Refer to Figure 9). 16. Remove the driveshaft assembly by holding the inner tripod joint and interconnecting and pulling the driveshaft assembly straight out of the side gear and transaxle oil seal (Refer to Figure 10). WHEN REMOVING THE DRIVESHAFT ASSEMBLY, DO NOT ALLOW THE SPLINES OR THE SNAP RING DRAG ACROSS THE SEALING LIP OF THE TRANSAXLE OIL SEAL. CAUTION: WHEN INSTALLED, THE DRIVESHAFT ACTS AS A BOLT AND SECURES THE FRONT HUB/BEARING ASSEMBLY. IF THE VEHICLE IS TO BE SUPPORTED OR MOVED ON ITS WHEELS, INSTALL A BOLT AND NUT THROUGH THE HUB/BEARING ASSEMBLY TO PREVENT LOOSING OF THE ASSEMBLY. 17. Lightly lubricate the transaxle oil seal sealing surface of the revised driveshaft assembly (P/N 4670280 Without ABS, P/N 4670282 With ABS) with clean transmission fluid. 18. Hold the revised driveshaft assembly at the tripod joint and the interconnecting shaft, align the tripod joint splines with the transaxle side gear splines and insert the tripod joint as far as possible by hand. WHEN INSTALLING THE DRIVESHAFT ASSEMBLY, DO NOT ALLOW THE SPLINES OR THE SNAP RING DRAG ACROSS THE SEALING LIP OF THE TRANSAXLE OIL SEAL. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6215 19. Grasp the driveshaft interconnecting shaft and firmly push the tripod joint into the transaxle side gear until fully seated. Test for snap ring engagement by trying to remove the tripod joint from the transaxle side gear by hand. If the snap ring is fully engaged with the side gear, the tripod will not be removable by hand. Figures 11-12 20. Clean any debris and moisture out of the area of the steering knuckle the driveshaft C/V joint will be installed (Refer to Figure 11). 21. Clean any debris and moisture from the driveshaft C/V joint before assembling it into the steering knuckle (Refer to Figure 12). Figures 13-14 22. Align the splines of the driveshaft C/V joint and the hub, then slide the shaft into the hub. Install the steering knuckle onto the ball joint stud (Refer to Figure 13). 23. Install the ball joint stud clamping bolt and nut then torque them to 70 ft. lbs. (95 Nm) (Refer to Figure 5). 24. Install the tie rod end into the steering knuckle. Hold the stud of the tie rod end with a 11/32 in, socket and tighten the tie rod end to steering knuckle attaching nut. Use a crowfoot to torque the nut to 45 ft. lbs. (61 Nm) (Refer to Figure 14). 25. Install the brake disc on the hub and bearing assembly. 26. Install the disc brake caliper assembly on the steering knuckle by sliding the top of the caliper under the top abutment on the caliper and the bottom of the caliper against the bottom abutment of the steering knuckle. 27. Install the caliper assembly to the steering knuckle attaching bolts and torque to 23 ft. lbs. (31 Nm). 28. Clean the threads of the driveshaft stub axle. Install and tighten the hub nut and washer on the driveshaft stub axle. 29. With the brakes applied to keep the driveshaft from turning, torque the hub nut to 135 ft. lbs. (183 Nm). 30. Install the tire/wheel assembly. Torque the lug nuts to 100 ft. lbs. (135 Nm). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6216 Figure 15 31. Install the spring washer, hub nut lock and new cotter pin (Refer to Figure 15). 32. Lower the vehicle. 33. With the vehicle positioned on a level surface, set the parking brake, start the engine and allow to idle in Park for a minimum of 1 minute. 34. Wipe all dirt from the transaxle dipstick area. 35. Check the fluid level on the transaxle dipstick. Proper fluid level is indicated when the fluid level is near the add mark and the fluid temperature is 70 degrees Fahrenheit (21 degrees Celsius) or when the fluid level is in the hot region of the dipstick when the transaxle is at operating temperature. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-13-05-94.......................................................................................................................................... ................................0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash Technical Service Bulletin # 020195 Date: 950127 Front Drive Axle - Vibration in Floor/Dash NO: 02-01-95 GROUP: Front Suspension DATE: Jan. 27, 1995 SUBJECT: Vibration in Floor Pan/Dash Panel 2800 to 4200 RPM Range MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AUTOMATIC TRANSAXLES AND BUILT PRIOR TO OCT. 24, 1994 (MDH 10-24-XX). SYMPTOM/CONDITION: Right side driveshaft vibration coming from the engine compartment and occurring between 2800 and 4200 RPM. The vibration is most noticeable at approximately 3200 RPM and may be felt in the floor pan and/or in the dash panel. DIAGNOSIS: 1. Start the vehicle and place the transmission in neutral or park. Set the parking brake. 2. Slowly depress the accelerator pedal until the engine reaches approximately 4800 RPM. Pay particular attention for any vibration (other than normal engine/exhaust vibrations) starting at around the 2800 RPM and most evident around 3200 RPM, then getting less noticeable and disappearing around 4200 RPM. The vibration may be felt in the floor pan and/or in the dash. 3. If a vibration is felt that starts and disappears at the RPM ranges listed above, perform the repair procedure. If the vibration does not conform to these RPM ranges, follow the vibration diagnostic procedure listed in the 1995 Service Manual. PARTS REQUIRED: 1 4670280 Driveshaft - ATX Without ABS -Rt 1 4670282 Driveshaft - ATX With ABS -Rt 1 6500336 Pin, Cotter Service Procedure REPAIR PROCEDURE: This bulletin involves replacing the right side driveshaft with a revised part. Figures 1-2 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6222 1. Remove the cotter pin, nut lock and spring washer (Refer to Figure 1) from the end of the right driveshaft. CAUTION: DO NOT ROLL THE VEHICLE ON THE GROUND AFTER THE HUB NUT IS LOOSENED. BEARING DAMAGE WILL RESULT. 2. Loosen but do not remove the hub nut while the weight of the vehicle is supported on the right tire/wheel assembly and the brakes are applied. 3. Raise the vehicle on a frame contact type hoist. 4. Remove the right front tire/wheel assembly from the hub. 5. Remove the right front disc brake caliper to steering knuckle attaching bolts (Refer to Figure 2). Figures 3-4 6. Remove the disc brake caliper assembly from the steering knuckle. The caliper is removed by first lifting the bottom of the caliper away from the steering knuckle, then removing the top of the caliper out from under the steering knuckle (Refer to Figure 3). 7. Support the caliper assembly using a wire hook. DO NOT ALLOW THE CALIPER ASSEMBLY TO HANG BY THE BRAKE FLEX HOSE. 8. Remove the brake disc from the front hub. 9. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud with a 11/32 in. socket while loosening the attaching nut (Refer to Figure 4). Figures 5-6 10. Use Special Tool MB 990635 to remove the tie rod end stud from the steering knuckle (Refer to Figure 5). 11. Remove the nut and bolt clamping the ball joint stud into the steering knuckle (Refer to Figure 6). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6223 Figures 7-8 12. Separate the ball joint stud from the steering knuckle by prying down on the lower control arm (Refer to Figure 7). USE CAUTION WHEN SEPARATING THE BALL JOINT FROM THE STEERING KNUCKLE SO THE BALL JOINT SEAL IS NOT DAMAGED. 13. Pull the steering knuckle out/away from the end of the driveshaft (Refer to Figure 8). 14. Support the outer end of the driveshaft. Figures 9-10 15. Remove the driveshaft from the transaxle side gear by placing a brass drift/punch against the inner tripod joint and hitting it sharply to dislodge the snap ring (Refer to Figure 9). 16. Remove the driveshaft assembly by holding the inner tripod joint and interconnecting and pulling the driveshaft assembly straight out of the side gear and transaxle oil seal (Refer to Figure 10). WHEN REMOVING THE DRIVESHAFT ASSEMBLY, DO NOT ALLOW THE SPLINES OR THE SNAP RING DRAG ACROSS THE SEALING LIP OF THE TRANSAXLE OIL SEAL. CAUTION: WHEN INSTALLED, THE DRIVESHAFT ACTS AS A BOLT AND SECURES THE FRONT HUB/BEARING ASSEMBLY. IF THE VEHICLE IS TO BE SUPPORTED OR MOVED ON ITS WHEELS, INSTALL A BOLT AND NUT THROUGH THE HUB/BEARING ASSEMBLY TO PREVENT LOOSING OF THE ASSEMBLY. 17. Lightly lubricate the transaxle oil seal sealing surface of the revised driveshaft assembly (P/N 4670280 Without ABS, P/N 4670282 With ABS) with clean transmission fluid. 18. Hold the revised driveshaft assembly at the tripod joint and the interconnecting shaft, align the tripod joint splines with the transaxle side gear splines and insert the tripod joint as far as possible by hand. WHEN INSTALLING THE DRIVESHAFT ASSEMBLY, DO NOT ALLOW THE SPLINES OR THE SNAP RING DRAG ACROSS THE SEALING LIP OF THE TRANSAXLE OIL SEAL. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6224 19. Grasp the driveshaft interconnecting shaft and firmly push the tripod joint into the transaxle side gear until fully seated. Test for snap ring engagement by trying to remove the tripod joint from the transaxle side gear by hand. If the snap ring is fully engaged with the side gear, the tripod will not be removable by hand. Figures 11-12 20. Clean any debris and moisture out of the area of the steering knuckle the driveshaft C/V joint will be installed (Refer to Figure 11). 21. Clean any debris and moisture from the driveshaft C/V joint before assembling it into the steering knuckle (Refer to Figure 12). Figures 13-14 22. Align the splines of the driveshaft C/V joint and the hub, then slide the shaft into the hub. Install the steering knuckle onto the ball joint stud (Refer to Figure 13). 23. Install the ball joint stud clamping bolt and nut then torque them to 70 ft. lbs. (95 Nm) (Refer to Figure 5). 24. Install the tie rod end into the steering knuckle. Hold the stud of the tie rod end with a 11/32 in, socket and tighten the tie rod end to steering knuckle attaching nut. Use a crowfoot to torque the nut to 45 ft. lbs. (61 Nm) (Refer to Figure 14). 25. Install the brake disc on the hub and bearing assembly. 26. Install the disc brake caliper assembly on the steering knuckle by sliding the top of the caliper under the top abutment on the caliper and the bottom of the caliper against the bottom abutment of the steering knuckle. 27. Install the caliper assembly to the steering knuckle attaching bolts and torque to 23 ft. lbs. (31 Nm). 28. Clean the threads of the driveshaft stub axle. Install and tighten the hub nut and washer on the driveshaft stub axle. 29. With the brakes applied to keep the driveshaft from turning, torque the hub nut to 135 ft. lbs. (183 Nm). 30. Install the tire/wheel assembly. Torque the lug nuts to 100 ft. lbs. (135 Nm). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 020195 > Jan > 95 > Front Drive Axle - Vibration in Floor/Dash > Page 6225 Figure 15 31. Install the spring washer, hub nut lock and new cotter pin (Refer to Figure 15). 32. Lower the vehicle. 33. With the vehicle positioned on a level surface, set the parking brake, start the engine and allow to idle in Park for a minimum of 1 minute. 34. Wipe all dirt from the transaxle dipstick area. 35. Check the fluid level on the transaxle dipstick. Proper fluid level is indicated when the fluid level is near the add mark and the fluid temperature is 70 degrees Fahrenheit (21 degrees Celsius) or when the fluid level is in the hot region of the dipstick when the transaxle is at operating temperature. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-13-05-94.......................................................................................................................................... ................................0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal Axle Shaft: Service and Repair Removal The content of this article reflects the changes called out by TSB 26-01-95. REMOVAL CAUTION: - Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage. - The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.). This will ensure that the hub bearing cannot loosen. 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. 2. Loosen (but do not remove) stub axle-to-hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact-type hoist. 4. Remove front tire and wheel assembly from the hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6228 5. Remove front disc brake caliper assembly to steering knuckle bolts. 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook, not by the brake flex hose. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6229 8. Remove braking disc from front hub. 9. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure: Hold tie rod end stud with a 11/32 socket while loosening and removing nut. 10. Remove the tie rod end stud from steering knuckle arm using Special Tool MB-990630, or equivalent. 11. Remove nut and bolt retaining ball joint stud into steering knuckle. NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6230 12. Separate ball joint stud from steering knuckle by prying down on lower control arm. NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow driveshaft to hang by inner ON joint, driveshaft must be supported. 13. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. 14. Support outer end of the driveshaft assembly. NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6231 15. Remove the inner tripod joints from the side gears of the transaxle using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear. 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6232 Axle Shaft: Service and Repair Installation The content of this article reflects the changes called out by TSB 26-01-95. INSTALLATION CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved an its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft lbs.). This will ensure that the hub bearing cannot loosen. 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install Tripod joint into transaxle side gear as far as possible by hand. 3. Carefully align tripod joint with transaxle side gears. Then grasp driveshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle. 5. Ensure that front of outer C/V joint, which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6233 6. Slide driveshaft back into front hub. Install steering knuckle onto the ball joint stud. 7. Install a NEW steering knuckle to ball joint stud clamping bolt and nut. Tighten the nut and bolt to 95 Nm (70 ft. lbs.). 8. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Then, using a crowfoot and 11/32 socket, tighten tie rod end nut to 61 Nm (45 ft. lbs.). 9. Install braking disc back on hub and bearing assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6234 10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 11. Install caliper assembly to steering knuckle bolts. Tighten to 31 Nm (23 ft. lbs.). 12. Clean all foreign matter from threads of outer C/V joint stub axle. Install hub nut and washer onto the threads of the stub axle and tighten nut. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6235 13. With vehicle brakes applied to keep axle shaft from turning, tighten hub nut to 183 Nm (135 ft. lbs.). 14. Install spring washer, hub nut lock and new cotter pin on outer C/V joint stub axle. Wrap the cotter pin prongs tightly around the hub nut lock. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten to 135 Nm (100 ft. lbs.). 16. Check for correct fluid level in transaxle assembly. 17. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 6236 Axle Shaft: Service and Repair Overhaul NOTE: The only service that is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. NOTE: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair Constant Velocity Joint Boot: Service and Repair Removal 1. Remove driveshaft as outlined under Driveshaft Replacement. 2. Remove inner joint boot clamps then slide boot down interconnecting shaft. 3. Remove interconnecting shaft and spider assembly out of joint housing. 4. Remove snap ring then spider assembly from interconnecting shaft using a brass drift if necessary. Do not hit the outer tripod bearings when removing spider assembly. 5. Remove joint boot from interconnecting shaft. 6. Clean and inspect spider assembly, tripod joint housing and interconnecting shaft for any signs of excessive wear. If any excessive wear is present, replacement of entire driveshaft will be necessary. Installation Two different types of boots are used on these models, a high temperature, soft and pliable type and a normal temperature, stiff and rigid type. The replacement boot must be the same type which was removed. 1. Install new boot clamps and boot onto interconnecting shaft. 2. Install spider assembly onto interconnecting shaft then the retaining snap ring. Ensure retaining snap ring is fully installed. 3. Distribute 1/2 the amount of grease provided in boot service package into tripod housing and the remaining amount into boot. 4. Install spider assembly into tripod housing. 5. Position boot over boot retaining grove on interconnecting shaft and install boot retaining clamp using Crimper tool No. C-4975 or equivalent. 6. Position boot into tripod housing retaining groove. Fig. 4 Driveshaft Removal, 90-91 Colt Wagon And Colt Vista 7. Prior to crimping boot clamp, the inner tripod joint must be at correct stroke position as shown. This ensures proper amount of air is inside sealing boot before clamp is crimped. Failure to perform this step will result in inner boot failure. 8. After adjusting stroke position, crimp boot clamp using Crimper tool. 9. Install driveshaft as outlined under "Driveshaft, Replace." Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: Customer Interest Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 6248 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: All Technical Service Bulletins Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 6254 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6257 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6258 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 6268 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Nut 20 ft.lb NOTE: Plus an additional 1/4 turn. Large End Bore Diameter 2.0075-2.0081 in Total Weight 1.20 lb (US) Bearing Oil Clearance 0.001-.0023 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 180496 > Feb > 96 > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 180496 > Feb > 96 > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 6280 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 182095A > Dec > 95 > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 182095A > Dec > 95 > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 6291 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 182095A > Dec > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 182095A > Dec > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 6297 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 182095A > Dec > 95 > Component Information > Technical Service Bulletins > Page 6298 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 203 Nm (150 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 6299 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6305 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6306 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6307 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6308 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6309 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Torque Torque Flex Plate to Crankshaft 70 ft lbs Flex Plate to Torque Conveter 50 ft lbs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications CAPACITY ........................................................................................................................................... ............................................................ 2.1 l (2.2 qt) TYPE .................................................................. ........................................................................................................................... MOPAR Type M.S.9417 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Hub: Customer Interest M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6326 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Hub: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6332 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Ring: Customer Interest M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6341 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Ring: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6347 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Technical Service Bulletins > M/T - Output Bearing Service Procedure Revision Output Shaft Bearing: Technical Service Bulletins M/T - Output Bearing Service Procedure Revision NUMBER: 26-04-96E GROUP: Miscellaneous DATE: Apr. 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-370-5025 DESCRIPTION OF CHANGES Changes to the transaxle output bearing procedure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Technical Service Bulletins > M/T - Output Bearing Service Procedure Revision > Page 6352 21-21 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shifter M/T: Customer Interest M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Shifter M/T: Customer Interest M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6365 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shifter M/T: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Shifter M/T: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6375 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter M/T: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, M/T: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter M/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6381 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter M/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6387 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shift Cable: Customer Interest M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Shift Cable: Customer Interest M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6401 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shift Cable: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Shift Cable: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6411 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 6412 Shift Cable: Adjustments The gearshift selector cable is not adjustable. If adjustment is required, only the crossover cable may be adjusted. 1. Remove gearshift console from vehicle. Gearshift Crossover Cable Adjustment 2. Loosen crossover cable adjustment screw. Crossover Lever Attachment To Transaxle 3. Using a 1/4 inch drill bit or suitable equivalent, pin crossover cable lever to transaxle. Ensure drill bit engages through crossover lever into transaxle case at least one half inch. 4. Ensure shift lever is in the spring loaded neutral position. If necessary, move lever forward and back, then allow lever to fall into it's natural neutral position. 5. Without allowing movement in either cable or lever, hand tighten crossover cable adjustment screw, then tighten screw to specifications. 6. Remove pin from transaxle crossover lever, then check transaxle shift functions. 7. Install gearshift console. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 6413 Shift Cable: Service and Repair NOTE: Use this procedure if either of the shift cables require replacement. REMOVAL AND INSTALLATION 1. Disconnect Power Distribution Center from battery tray and set aside. 2. Remove air cleaner inlet horn. 3. Remove battery and battery tray. Shift Cable Removal 4. Disconnect gear shift cable ends from transaxle shift levers. CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 5. Remove cable to bracket retaining clips at transaxle. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 6. Pull cables up out of transaxle bracket. 7. Remove console from vehicle. Cable Retaining Clips 8. Remove floor pan grommet retaining nuts. 9. Remove cable retaining clips at shifter. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 10. Disconnect shift cables from shifter. Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 6414 Shift Cable Floor Grommet 11. Lift vehicle on hoist. Remove self tapping screws securing grommet plate to underbody heat shield and floor pan. 12. Detach cables from cable support clip in tunnel above exhaust catalyst. 13. Remove shift cables from vehicle. To install, reverse removal procedure. After cables have been replaced, cable adjustment should be checked. CAUTION: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, M/T: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, M/T: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, M/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6423 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, M/T: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, M/T: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, M/T: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6429 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6458 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 6469 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6470 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6471 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Park Neutral Safety Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6500 Transmission Position Switch/Sensor: Description and Operation Fig. 14 Park/Neutral Switch PURPOSE The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection), and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral position switch is located on the automatic transaxle housing (Fig. 14). Manual transaxles do not use park/neutral switches. CIRCUIT OPERATION When closed, the PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. The case-grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay Circuit T41 connects to cavity 2 of the PARK/NEUTRAL position switch connector. Circuit T41 splices to cavity 50 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. NOTE: The park/neutral switch is sometimes referred to as the neutral safety switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > Helpful Information Transmission Position Switch/Sensor: Testing and Inspection Helpful Information In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 amp maxi fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > Customer Interest: > 050294 > Feb > 94 > ABS - Warning Lamp ON Anti-Lock Warning Lamp: Customer Interest ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 050294 > Feb > 94 > ABS - Warning Lamp ON Anti-Lock Warning Lamp: All Technical Service Bulletins ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Lock Warning Lamp: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Gear, A/T: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Lock Warning Lamp: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6523 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Lock Warning Lamp: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 6529 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > Page 6530 Anti-Lock Warning Lamp: Description and Operation The Antilock Brake System (ABS) warning lamp located on the instrument cluster will turn on when the CAB detects a condition which results in a shutdown of the ABS function. The ABS warning lamp will turn on for approximately four-five seconds after the ignition key is switched to the ON position. During this time the CAB runs a system self test. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The relay box is mounted on the Hydraulic Control Unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 6534 ABS Main Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 6535 ABS Main Relay: Description and Operation ABS SYSTEM RELAY The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the control module. Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the left headlamp ground. When the system is operating normally, power for the contact side of the relay is supplied from the control module on the B47 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F18 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Data Link Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 6542 Data Link Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: Customer Interest ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: All Technical Service Bulletins ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 6556 ABS Control Module: Locations ABS Controller The controller is located in the passenger compartment, on the left kick panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 6557 Controller Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 6558 ABS Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 6559 ABS Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates Hydraulic Control Unit: Technical Service Bulletins Brake Master Cylinder - Manual Updates NO: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 SUBJECT: Service Manual Revision - Brake System Master cylinder MODELS: 1995 (PL) Neon DISCUSSION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6564 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6565 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6566 This technical service bulletin contains revised service manual pages. The revisions are marked with **ASTERISKS**. Please insert the attached revised service manual pages in the appropriate Service Manual. MANUAL PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 5-67 Push Rod Lubricant 5-72 Push Rod Lubricant 5-86 Push Rod Lubricant NOTE: THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE SERVICE MANUAL PERMANENT AND LESS CUMBERSOME. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6567 Hydraulic Control Unit: Locations The Hydraulic Control Unit is located below the master cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6568 Hydraulic Control Unit: Diagrams Modulator Connector Modulator Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6569 Hydraulic Control Unit: Description and Operation The Hydraulic Control Unit (HCU) is located under the master cylinder. The HCU contains the following components for controlling brakes during ABS braking; four decay valves, four shuttle valves, two fluid sumps, a pump/motor and a relay box. Also attached to the HCU are rear brake proportioning valves and the six hydraulic tubes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6570 Hydraulic Control Unit: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL 1. Disconnect battery ground cable and isolate cable. 2. Disconnect brake fluid level sensor electrical connector at base of master cylinder. 3. Disconnect primary and secondary brake tubes from master cylinder. Install plugs into master cylinder brake tube outlets. 4. Use a suitable brake cleaner to clean area where master cylinder attaches to power booster. 5. Pump brake pedal until it is firm. This will pump down the vacuum inside the power booster and prevent the booster from sucking in any contamination when removing the master cylinder. 6. Remove master cylinder to power booster retaining nuts, then slide master cylinder straight out. 7. Disconnect 6-way electrical connector from Hydraulic Control Unit (HCU) wiring harness and 10-way electrical connector from HCU relay box. 8. Remove primary and secondary master cylinder brake tubes from HCU. 9. Remove remaining brake tubes from proportioning valves and HCU outlet ports. 10. Raise and support vehicle. 11. Remove two bolts attaching HCU mounting bracket to side of front of frame rail. 12. Lower vehicle and remove bolts attaching HCU mounting bracket to top of frame rail. 13. Remove HCU and mounting bracket as an assembly from vehicle. INSTALLATION 1. Install HCU and mounting bracket as an assembly, on left frame rail of vehicle, aligning tabs on mounting bracket with holes in frame rail. 2. Install and loosely tighten bolt attaching HCU mounting bracket to top of frame rail. 3. Raise and support vehicle. 4. Install two bolts attaching HCU mounting bracket to side of front frame rail. Torque bolts to 16 ft. lbs. 5. Lower vehicle and torque bolt attaching HCU mounting bracket to top of frame rail to 9 ft. lbs. 6. Install four chassis brake tubes to HCU proportioning valves and outlet ports, torque brake tube nuts to 12 ft. lbs. 7. Install primary and secondary brake tubes from master cylinder onto HCU, then hand tighten tube nuts. 8. Connect electrical connectors to HCU. Fig 61 Power Brake Booster Vacuum Seal Removal 9. Using a small screwdriver, carefully remove vacuum seal from front of power brake booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 10. Remove old vacuum seal from master cylinder, if seal came out of power brake vacuum booster when master cylinder was removed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6571 Fig 62 Power Brake Booster Vacuum Seal Installation 11. Lubricate master cylinder push rod with Mopar Silicone Dielectric Compound - NO Substitutes. Then install new vacuum seal onto master cylinder push rod as shown. 12. Position master cylinder on studs of power brake booster, aligning push rods of power brake booster and master cylinder. 13. Install two master cylinder mounting nuts and torque to 21 ft. lbs. 14. Connect primary and secondary tubes to master cylinder and HCU. Torque brake tube nuts at master cylinder to 12 ft. lbs. and torque brake tube nuts at HCU to 15 ft. lbs. 15. Connect brake fluid level sensor electrical connector. 16. Bleed brake system as described in Hydraulic System/Service and Repair/Brake System Bleed procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6576 39 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6577 43 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6578 45 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6579 47 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6580 51 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6581 55 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6582 57 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6583 59 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6584 63 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6585 67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6586 69 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6587 71 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6588 173 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6589 177 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6590 179 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6591 181 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6592 187 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6593 191 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6594 193 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6595 195 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6596 201 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6597 205 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6598 207 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6599 209 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6600 256 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel Speed Sensors 1800 - 2600 ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 6603 Wheel Speed Sensor: Mechanical Specifications Wheel Speed Sensor/Tone Wheel Air Gap 0.04 - 1.67 mm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Wheel Speed Sensor: Locations Front Wheel Speed Sensors Wheel Speed Sensor The front wheel speed sensors are located on the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 6606 Wheel Speed Sensor: Locations Rear Wheel Speed Sensors Wheel Speed Sensor The rear wheel speed sensors are located on the rear brake support plate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 6609 Wheel Speed Sensor: Diagrams Rear Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 6610 Wheel Speed Sensor: Description and Operation One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 6611 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 6617 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Description Brake Warning Indicator: Description and Operation ABS Warning Lamp Description ANTI-LOCK WARNING LAMP The Anti-Lock Warning lamp is used to alert the driver of a problem in the ABS system. When the ABS controller recognizes a problem in the system, it grounds the G19 circuit, which illuminates the lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Description > Page 6622 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description BRAKE WARNING LAMP The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicle's braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self-check. There are two switches used in this system and they are wired in parallel. A parking brake switch, located on the parking brake mechanism, illuminates the lamp if the normally open switch is closed. This switch is case-grounded. The other switch used is the Brake Warning lamp switch. This switch is normally open. When the brake system pressure is below a predetermined level, the switch closes and completes a path to ground from the G9 circuit at the cluster, through the switch, then to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). For further information on the DRL refer to the Front Lighting System section. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 6623 Brake Warning Indicator: Testing and Inspection Normal Operation The brake warning lamp illuminates when parking brake is applied with ignition key turned ON. The same lamp will also illuminate should one of the two service brake systems fail when brake pedal is applied. TO TEST SYSTEM: 1. Turn the ignition switch to the start position. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - Broken or disconnected wire at the switch 2. Turn ignition switch to ON position and apply parking brake. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - Broken or disconnected wire at the switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions Brake Caliper: Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6629 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6630 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6631 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6632 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6633 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Bore and Piston Dimensions Caliper Piston Outside Diameter 2.125 in Caliper Piston Diameter Solid 1.34 in Vented 1.42 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 6636 Brake Caliper: Specifications Torque Specs Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Bearing Retainer Bolts 21 ft.lb Brake Hose To Caliper Banjo Bolt 35 ft.lb Brake Line Fitting 12 ft.lb Support Plate To Rear Axle 80 ft.lb Bleed Screws 10 ft.lb Caliper Mounting Bolts 16 ft.lb Caliper Guide Pins 30 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front 1. Remove caliper as outlined under Brake Pad/Service and Repair. 2. Disconnect Brake Line. 3. Reverse procedure to install, bleed brakes as outlined under Hydraulic System/ Service and Repair/Brake System Bleed. Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 6639 Brake Caliper: Service and Repair Disassembly and Assembly Front DISASSEMBLE 1. Remove caliper assembly as described under Brake Pad/Service and Repair. 2. Place a wood block between caliper piston and caliper fingers. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If piston are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. Remove caliper bushings. ASSEMBLE 1. Mount caliper in a soft jawed vise. 2. Lubricate piston seal with clean brake fluid and install seal in caliper bore groove. Ensure seal is properly seated. 3. Lubricate piston boot with clean brake fluid and position over piston. 4. Install piston and boot assembly, pushing it past piston seal until it bottoms into caliper bore. 5. Using a hammer and dust boot installer tool No. C-4689 with handle tool No. C-4171, or equivalents, drive dust boot into counterbore until properly seated. 6. On models where bushings require replacement, compress flanges of bushings and install on caliper housing. Ensure bushing flanges extend evenly over caliper housing on both sides. Remove Teflon sleeves from guide pin bushings prior to installing bushings into caliper. After bushings are installed into caliper, reinstall Teflon sleeves into bushings. 7. Connect brake hose to brake line at frame bracket. . Install caliper on vehicle as described under Brake Pad/Service and Repair. 9. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Rear 1. Remove caliper from rotor as described under Brake Pad/Service and Repair. 2. Place a small piece of wood between piston and caliper fingers, then carefully depress brake pedal to hydraulically push piston out of bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. If necessary, remove bushing and sleeve assembly, as follows: a. Using fingers, push inner sleeve until it pops out of bushing, then pull inner sleeve completely out of bushing. b. Using fingers collapse one side of bushing. Pull opposite side of bushing to remove from caliper. 9. Using denatured alcohol or equivalent, thoroughly clean piston and caliper grooves, caliper housing and bushing mounting surfaces. 10. Dip new piston seal in clean brake fluid and install in groove in bore. 11. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 12. Coat piston with clean brake fluid, then position dust boot over piston. 13. Install piston into bore pushing it past piston seal until it bottoms in bore. 14. Position dust boot in counterbore, then using a hammer and installer tool No. C-4383-7, or equivalent, drive boot into counterbore of caliper. 15. If removed, install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section. b. Using fingers, insert folded bushing into caliper. Do not use sharp object to perform this step. c. Using wooden dowel, unfold bushing until it is fully seated in caliper. Flanges should be seated evenly on both sides of bushing hole. 16. If removed, install guide pin sleeve as follows: a. Hold end of bushing, then push sleeve through bushing until end of bushing is fully seated into seal groove of sleeve. b. Holding sleeve in place, install other end of bushing into seal groove. c. Ensure bushing is in seal groove on both sides. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 6640 17. Install brake fluid line, then install caliper as outlined under Brake Pad/Service and Repair. 18. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: Customer Interest Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 051994 > Sep > 94 > Front Brake Pads - Grinding or Squeaking Noise Brake Pad: Customer Interest Front Brake Pads - Grinding or Squeaking Noise NO: 05-19-94 GROUP: Brakes DATE: Oct. 7, 1994 SUBJECT: Premature Front Brake Pad Wear MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 4-STUD WHEELS WITH SALES CODE BRC OR BRH BRAKE SYSTEMS. SYMPTOM/CONDITION: Grinding or squeaking noise from front brakes. This condition can result from premature front pad wear in city commuter type driving when the brakes are operating at elevated temperatures for extended periods of time. DIAGNOSIS: Inspect the front disc brake lining. If one or more of the front brake pads are excessively worn, proceed with the following repair. PARTS REQUIRED: 1 4797411 Front Lining Set REPAIR PROCEDURE: This bulletin involves replacing the front disc brake lining with a heavy duty lining set. NOTE: THIS HEAVY DUTY FRONT LINING IS NOT RECOMMENDED FOR REPLACEMENT ON VEHICLES WITH FRONT BRAKE NOISE COMPLAINTS THAT DO NOT EXHIBIT PREMATURE WEAR. USE P/N 4762550 BRAKE LINING FOR NORMAL REPLACEMENT. 1. Replace the front disc brake lining with P/N 4797411. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: All Technical Service Bulletins Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 051994 > Sep > 94 > Front Brake Pads Grinding or Squeaking Noise Brake Pad: All Technical Service Bulletins Front Brake Pads - Grinding or Squeaking Noise NO: 05-19-94 GROUP: Brakes DATE: Oct. 7, 1994 SUBJECT: Premature Front Brake Pad Wear MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 4-STUD WHEELS WITH SALES CODE BRC OR BRH BRAKE SYSTEMS. SYMPTOM/CONDITION: Grinding or squeaking noise from front brakes. This condition can result from premature front pad wear in city commuter type driving when the brakes are operating at elevated temperatures for extended periods of time. DIAGNOSIS: Inspect the front disc brake lining. If one or more of the front brake pads are excessively worn, proceed with the following repair. PARTS REQUIRED: 1 4797411 Front Lining Set REPAIR PROCEDURE: This bulletin involves replacing the front disc brake lining with a heavy duty lining set. NOTE: THIS HEAVY DUTY FRONT LINING IS NOT RECOMMENDED FOR REPLACEMENT ON VEHICLES WITH FRONT BRAKE NOISE COMPLAINTS THAT DO NOT EXHIBIT PREMATURE WEAR. USE P/N 4762550 BRAKE LINING FOR NORMAL REPLACEMENT. 1. Replace the front disc brake lining with P/N 4797411. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-23-97 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front REMOVAL 1. Remove half of brake fluid from reservoir. 2. Raise and support front of vehicle. 3. Remove wheel and tire assembly. 4. Remove caliper guide pin bolts, then wedge caliper away from rotor using a screwdriver to break gasket adhesive seals. 5. Remove caliper by slowly sliding assembly out and away from rotor. NOTE: Suspend caliper with wire to avoid damaging brake hose. 6. Remove outboard pad, then the inboard pad by sliding off of adapter. INSTALLATION 1. Lubricate adapter ways with suitable grease. 2. Install inboard pad, then the outboard pad onto adapter. 3. Lower caliper over rotor and pad assemblies, then install guide pins. Tighten pins to specifications. 4. Install tire and wheel assembly, then lower vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6664 Brake Pad: Service and Repair Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Technical Service Bulletins > Customer Interest for Brake Disc: > 051694A > Jan > 95 > Front Brakes - Moaning Noises Brake Disc: Customer Interest Front Brakes - Moaning Noises NO: 05-16-94 Rev. A GROUP: Brakes DATE: Jan. 13, 1995 SUBJECT: Moaning Noise from Front Brakes THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-16-94 DATED SEP. 9, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PROCEDURE HAS BEEN CHANGED TO REPLACE RATHER THAN REFACE FRONT DISC BRAKE ROTORS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 1/3/95 (MDH O1-03-XX) EQUIPPED WITH FOUR (4) STUD HUBS, SALES CODES BRC AND BRH.** SYMPTOM/CONDITION: A low frequency moan, growl or a grinding noise that can be heard when stopping during moderate to heavy braking. The sound varies with vehicle speed and usually occurs when braking above 45 MPH. DIAGNOSIS: With the windows closed, radio and the heater/AC system off, road test the vehicle on a smooth road surface and apply the brakes heavily from a speed above 45 MPH. Avoid skidding the tires. if the noise is heard, proceed with the following repair. **PARTS REQUIRED: 2 4509715 Disk Brake Rotor** REPAIR PROCEDURE: **This bulletin involves replacing the front disc brake rotors with a revised part.** 1. Remove the disc brake rotors as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 5-45. 2. Install the disc brake rotors as outlined in the Service Manual, Page 546. NOTE: REPLACEMENT OF DISC BRAKE PADS IS NOT REQUIRED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Disc Brake Rotor. Replace. Left Side Labor Operation No: 05-21-10-91.......................................................................................................................................... ................................0.3 Hrs. Disc Brake Rotor. Replace. Right Side 05-21-10-92............................................................................ ..............................................................................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Disc: > 051694A > Jan > 95 > Front Brakes - Moaning Noises Brake Disc: All Technical Service Bulletins Front Brakes - Moaning Noises NO: 05-16-94 Rev. A GROUP: Brakes DATE: Jan. 13, 1995 SUBJECT: Moaning Noise from Front Brakes THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-16-94 DATED SEP. 9, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PROCEDURE HAS BEEN CHANGED TO REPLACE RATHER THAN REFACE FRONT DISC BRAKE ROTORS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 1/3/95 (MDH O1-03-XX) EQUIPPED WITH FOUR (4) STUD HUBS, SALES CODES BRC AND BRH.** SYMPTOM/CONDITION: A low frequency moan, growl or a grinding noise that can be heard when stopping during moderate to heavy braking. The sound varies with vehicle speed and usually occurs when braking above 45 MPH. DIAGNOSIS: With the windows closed, radio and the heater/AC system off, road test the vehicle on a smooth road surface and apply the brakes heavily from a speed above 45 MPH. Avoid skidding the tires. if the noise is heard, proceed with the following repair. **PARTS REQUIRED: 2 4509715 Disk Brake Rotor** REPAIR PROCEDURE: **This bulletin involves replacing the front disc brake rotors with a revised part.** 1. Remove the disc brake rotors as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 5-45. 2. Install the disc brake rotors as outlined in the Service Manual, Page 546. NOTE: REPLACEMENT OF DISC BRAKE PADS IS NOT REQUIRED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Disc Brake Rotor. Replace. Left Side Labor Operation No: 05-21-10-91.......................................................................................................................................... ................................0.3 Hrs. Disc Brake Rotor. Replace. Right Side 05-21-10-92............................................................................ ..............................................................................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Front Brake Disc: Specifications Nominal Thickness 0.782-0.792 in Minimum Refinish Thickness 0.724 in Thickness Variation (Parallelism) 0.0005 in Lateral Runout (T.I.R.) 0.005 in Finish, Micro-Inch 15-80 micro-in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Front > Page 6680 Brake Disc: Specifications Minimum Allowable Thickness Refer to stamping on rotor's un-machined surface. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Front Brake Disc: Service and Repair Front Remove caliper as outlined under Brake Caliper/Service and Repair, then remove rotor. Use a suitable soft face hammer if necessary to tap rotor free of hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Front > Page 6683 Brake Disc: Service and Repair Rear 1. Remove caliper as outlined under Brake Caliper/Service and Repair. 2. Remove parking brake adjustment hole plug from hub of brake disc. 3. Using a suitable tool, turn parking brake adjusting nut until brake disc can be removed. 4. Reverse procedure to install. Adjust parking brake as outlined under Parking Brake System/Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 6693 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop > Page 6699 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 6700 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake Drum Inside Diameter 7.927 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6707 Brake Drum: Testing and Inspection Any time the brake drums are removed for brake service, the braking surface diameter should be inspected with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Scoring and grooves in the braking surface can only be removed by machining with special equipment, as long as the braking surface is within specifications. Any brake drum showing taper or sufficiently out of round to cause vehicle vibration or noise while braking should also be machined, removing only enough stock to true up the drum. After a brake drum is machined, wipe the braking surface diameter with a denatured alcohol soaked cloth. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 050396 > Feb > 96 > Rear Brakes - Howl at The End of a Stop Brake Shoe: Customer Interest Rear Brakes - Howl at The End of a Stop N0. 05-03-96 GROUP: Brakes DATE: Feb. 23, 1996 SUBJECT: Rear Brake Howl MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: A howl noise coming from the rear brakes at the end of a stop, usually from 5 - 0 MPH. This noise can range from a low volume, to a very loud sound that may appear to come from the front brakes. NOTE: THIS REPAIR HAS NO EFFECT ON THE CYCLIC REAR BRAKE NOISE WHICH OCCURS AT LOW SPEEDS DURING MEDIUM TO LIGHT BRAKE APPLICATIONS. PARTS REQUIRED: 1 4762537 Rear Shoe and Lining Kit REPAIR PROCEDURE: This bulletin involves the replacement of the rear brake shoes with a new lining material. 1. Replace the rear brake shoes, following the procedure given in the 1996 Neon Service Manual (P/N 81-270-6025) on page 5-35. CAUTION: THIS REPAIR SHOULD BE PERFORMED WITHOUT TURNING THE BRAKE DRUMS (UNLESS DRUMS SHOW A MECHANICAL REASON). NEW BRAKE SHOE LINING ARE THE MOST EFFECTIVE REPAIR FOR THIS COMPLAINT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-06-98 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 050396 > Feb > 96 > Rear Brakes - Howl at The End of a Stop Brake Shoe: All Technical Service Bulletins Rear Brakes - Howl at The End of a Stop N0. 05-03-96 GROUP: Brakes DATE: Feb. 23, 1996 SUBJECT: Rear Brake Howl MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: A howl noise coming from the rear brakes at the end of a stop, usually from 5 - 0 MPH. This noise can range from a low volume, to a very loud sound that may appear to come from the front brakes. NOTE: THIS REPAIR HAS NO EFFECT ON THE CYCLIC REAR BRAKE NOISE WHICH OCCURS AT LOW SPEEDS DURING MEDIUM TO LIGHT BRAKE APPLICATIONS. PARTS REQUIRED: 1 4762537 Rear Shoe and Lining Kit REPAIR PROCEDURE: This bulletin involves the replacement of the rear brake shoes with a new lining material. 1. Replace the rear brake shoes, following the procedure given in the 1996 Neon Service Manual (P/N 81-270-6025) on page 5-35. CAUTION: THIS REPAIR SHOULD BE PERFORMED WITHOUT TURNING THE BRAKE DRUMS (UNLESS DRUMS SHOW A MECHANICAL REASON). NEW BRAKE SHOE LINING ARE THE MOST EFFECTIVE REPAIR FOR THIS COMPLAINT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-06-98 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Hub: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6726 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6732 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal 1. Raise and support rear of vehicle. 2. Remove tire and wheel assembly, then remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. Fig. 1 Kelsey-Hayes Leading Trailing Drum Brake Assembly. Type 2 3. Using suitable pliers, remove adjuster lever spring. 4. Remove adjuster lever. 5. Turn automatic adjuster screw out to expand shoes past wheel cylinder boot. 6. Disconnect parking brake cable from parking brake lever. 7. On Kelsey Hayes brake assemblies, using suitable tool, remove hold-down springs. Pull brake shoe assembly down and away from anchor plate, then remove brake shoe springs and adjusting screw assembly. Fig 3 Varga Leading Trailing Drum Brake Assembly 8. On Varga brake assemblies, remove upper shoe to shoe return spring on leading shoe, leading shoe hold-down spring, shoe to shoe spring at Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 6735 anchor plate, then the shoe and adjuster assembly. 9. On all models, remove hold-down spring and lower shoe to anchor plate spring for trailing shoe. 10. On Kelsey Hayes brake assemblies, remove C-clip retaining parking brake lever to trailing brake shoe webbing. 11. On Varga brake assemblies, remove parking brake lever from trailing shoe by prying retainer tangs apart. 12. On all models, clean dirt from brake drum, anchor plate and all other components. Do not use compressed air or dry brush to clean brake parts. Many brake parts contain asbestos fibers, which, if inhaled, can cause serious injury. To clean brake parts, use a water soaked rag or a suitable vacuum cleaner to minimize airborne dust. Installation KELSEY-HAYES BRAKE ASSEMBLY 1. Lightly lubricate anchor plate shoe contact surfaces with suitable brake lube. 2. Remove brake drum hub grease seal and bearings, then clean and repack bearings and reinstall. Install new grease seal. 3. Assemble automatic adjuster screw assembly, return spring and shoe-to-shoe spring to brake shoe assembly. 4. Position lining assembly near anchor plate, then assemble parking brake lever to trailing shoe webbing. Secure with C-clip. 5. Install lining assembly onto anchor plate. When positioned, back off adjuster nut to seat brake shoe ends in wheel cylinder. 6. Install hold-down springs. 7. Position adjuster lever, then using suitable pliers, install adjuster lever spring. 8. Install brake drum and bearings. Refer to individual car chapter for wheel bearing adjustment procedure. 9. Adjust brakes. 10. Install tire and wheel assembly. 11. If any hydraulic connections have been opened, bleed brake system. 12. Inspect master cylinder level, and replenish as necessary. 13. Inspect brake pedal for proper feel and return. 14. Lower vehicle and road test. Do not severely apply brakes immediately after installation of new brake linings or permanent damage may occur to linings and/or brake drums may become scored. Brakes must be used moderately during first several hundred miles of operation to ensure proper burnishing. VARGA BRAKE ASSEMBLY 1. Assemble park brake lever and wave washer to trailing shoe, then install retainer and close ends. 2. Install park brake cable in lever of trailing shoe, then attach trailing shoe and leading shoe lower springs to shoes and anchor plate. 3. Position shoes on support plate and install hold-down springs. 4. Install automatic adjusters, ends must be above extruded pins in web of shoe. Lefthand side adjuster has lefthand threads. Righthand side adjuster has righthand threads. Do not interchange them. 5. Install upper shoe to shoe spring, then rotate adjuster to remove freeplay from adjuster assembly. 6. Install adjuster lever on leading pivot pin and attach short end of adjuster spring in hole of lever and long end in leading shoe hole. 7. Connect park brake cable and adjust shoes so that they do not interfere with drum installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 6736 Brake Shoe: Service and Repair Cleaning and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exist, brake linings should be replaced as an axle set to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. Any component which exhibits overheating signs should be replaced. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above is found, replace as required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise Wheel Cylinder: Customer Interest Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise > Page 6745 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 6751 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6752 Wheel Cylinder: Specifications Bearing Retainer Bolts 160 ft.lb Brake Line Fittings 12 ft.lb Support Plate To Rear Axle 85 ft.lb Wheel Cylinder Bleed Screws 6 ft.lb Wheel Cylinder To Backing Plate 6 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel, drum and brake shoes. 2. Loosen brake line fitting at wheel cylinder. Do not pull metal line away from cylinder. 3. Remove screws holding cylinder to backing plate. 4. Separate wheel cylinder from brake line and backing plate by pulling the cylinder outward and away from backing plate. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Position wheel cylinder to backing plate. Install brake line to cylinder and start connecting fitting. 3. Secure wheel cylinder to backing plate, then complete tightening of brake line fitting. 4. Install brake shoes, drum and wheel. 5. Bleed system as outlined previously, and adjust brakes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 6755 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Note position of all parts as they are removed for proper installation. DISASSEMBLE Fig 28 Disassembled View Of Typical Wheel Cylinder 1. Remove boots, pistons, cups and spring from wheel cylinder. 2. Wipe cylinder walls with denatured alcohol or clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the bore diameter is not increased more than 0.005 inch. Replace as necessary. 4. Check pistons for wear or damage. Replace as necessary. ASSEMBLE 1. Before assembling, wash hands with soap and water so as not to contaminate rubber parts. 2. Use all parts contained in repair kit. Lubricate cylinder wall and rubber cups with brake fluid. 3. Properly install spring, cups, pistons and boots in housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 6762 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions Brake Caliper: Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6767 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6768 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6769 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6770 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Drivetrain/Brakes - Service Manual Revisions > Page 6771 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Bore and Piston Dimensions Caliper Piston Outside Diameter 2.125 in Caliper Piston Diameter Solid 1.34 in Vented 1.42 in Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 6774 Brake Caliper: Specifications Torque Specs Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Bearing Retainer Bolts 21 ft.lb Brake Hose To Caliper Banjo Bolt 35 ft.lb Brake Line Fitting 12 ft.lb Support Plate To Rear Axle 80 ft.lb Bleed Screws 10 ft.lb Caliper Mounting Bolts 16 ft.lb Caliper Guide Pins 30 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front 1. Remove caliper as outlined under Brake Pad/Service and Repair. 2. Disconnect Brake Line. 3. Reverse procedure to install, bleed brakes as outlined under Hydraulic System/ Service and Repair/Brake System Bleed. Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 6777 Brake Caliper: Service and Repair Disassembly and Assembly Front DISASSEMBLE 1. Remove caliper assembly as described under Brake Pad/Service and Repair. 2. Place a wood block between caliper piston and caliper fingers. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If piston are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. Remove caliper bushings. ASSEMBLE 1. Mount caliper in a soft jawed vise. 2. Lubricate piston seal with clean brake fluid and install seal in caliper bore groove. Ensure seal is properly seated. 3. Lubricate piston boot with clean brake fluid and position over piston. 4. Install piston and boot assembly, pushing it past piston seal until it bottoms into caliper bore. 5. Using a hammer and dust boot installer tool No. C-4689 with handle tool No. C-4171, or equivalents, drive dust boot into counterbore until properly seated. 6. On models where bushings require replacement, compress flanges of bushings and install on caliper housing. Ensure bushing flanges extend evenly over caliper housing on both sides. Remove Teflon sleeves from guide pin bushings prior to installing bushings into caliper. After bushings are installed into caliper, reinstall Teflon sleeves into bushings. 7. Connect brake hose to brake line at frame bracket. . Install caliper on vehicle as described under Brake Pad/Service and Repair. 9. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Rear 1. Remove caliper from rotor as described under Brake Pad/Service and Repair. 2. Place a small piece of wood between piston and caliper fingers, then carefully depress brake pedal to hydraulically push piston out of bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. If necessary, remove bushing and sleeve assembly, as follows: a. Using fingers, push inner sleeve until it pops out of bushing, then pull inner sleeve completely out of bushing. b. Using fingers collapse one side of bushing. Pull opposite side of bushing to remove from caliper. 9. Using denatured alcohol or equivalent, thoroughly clean piston and caliper grooves, caliper housing and bushing mounting surfaces. 10. Dip new piston seal in clean brake fluid and install in groove in bore. 11. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 12. Coat piston with clean brake fluid, then position dust boot over piston. 13. Install piston into bore pushing it past piston seal until it bottoms in bore. 14. Position dust boot in counterbore, then using a hammer and installer tool No. C-4383-7, or equivalent, drive boot into counterbore of caliper. 15. If removed, install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section. b. Using fingers, insert folded bushing into caliper. Do not use sharp object to perform this step. c. Using wooden dowel, unfold bushing until it is fully seated in caliper. Flanges should be seated evenly on both sides of bushing hole. 16. If removed, install guide pin sleeve as follows: a. Hold end of bushing, then push sleeve through bushing until end of bushing is fully seated into seal groove of sleeve. b. Holding sleeve in place, install other end of bushing into seal groove. c. Ensure bushing is in seal groove on both sides. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 6778 17. Install brake fluid line, then install caliper as outlined under Brake Pad/Service and Repair. 18. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > NHTSA96V228000 > Nov > 96 > Recall 96V228000: Brake & Fuel Line Corrosion Brake Hose/Line: Recalls Recall 96V228000: Brake & Fuel Line Corrosion The fuel and rear brake tubes can experience accelerated corrosion between the tubes and a rubber isolator. Corrosion of the tubes can lead to brake fluid or fuel leakage. This can cause a loss of brakes or result in a fire. Dealers will inspect the brake, fuel supply and fuel vapor tubes for the presence of corrosion. Any tubes showing corrosion will be replaced. All vehicles will have the rubber isolator replaced with a plastic clip. Owner notification began December 6, 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6791 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6792 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6793 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6794 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6795 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6796 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 705 > Nov > 96 > Recall - Brake/Fuel Tube Corrosion > Page 6797 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > NHTSA94V034000 > Feb > 94 > Recall 94V034000: Brake Line Bracket Screw Failure Brake Hose/Line: Recalls Recall 94V034000: Brake Line Bracket Screw Failure The rear brake hose mounting bracket screws can fail allowing the brake hoses to move out of position. The unrestrained hoses are then susceptible to damage which could result in brake fluid leakage. Brake fluid leakage will reduce the braking performance of the vehicle, extend stopping distances, and could result in an accident. The rear brake line hose bracket screws on these vehicles will be replaced. SYSTEM: BRAKES; HYDRAULIC; LINES; FITTINGS. VEHICLE DESCRIPTION: PASSENGER VEHICLES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OF NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > NHTSA96V228000 > Nov > 96 > Recall 96V228000: Brake & Fuel Line Corrosion Brake Hose/Line: All Technical Service Bulletins Recall 96V228000: Brake & Fuel Line Corrosion The fuel and rear brake tubes can experience accelerated corrosion between the tubes and a rubber isolator. Corrosion of the tubes can lead to brake fluid or fuel leakage. This can cause a loss of brakes or result in a fire. Dealers will inspect the brake, fuel supply and fuel vapor tubes for the presence of corrosion. Any tubes showing corrosion will be replaced. All vehicles will have the rubber isolator replaced with a plastic clip. Owner notification began December 6, 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion Technical Service Bulletin # 705 Date: 961101 Recall - Brake/Fuel Tube Corrosion No. 705 November 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 705 -- Brake/Fuel Tube Corrosion Models: 1995 Model Year Dodge/Plymouth Neon (PL) Vehicles Built Through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN Position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN Position) The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Tubes with white powder or other residue/discoloration do not require replacement. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. The fourth character of the recall number (formerly used to identify truck notifications with a "T") will be utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt belt (7052) according to Chrysler's records. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Retainer Clip Packages, Recall PN CAS27055, to service 100% of those vehicles. Each Retainer Clip parts package contains the following components: Quantity Description 1 Retainer Clip Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6811 1 Screw 4 Tie Strap (required for ABS equipped vehicles only) 1 Instruction Sheet In addition, involved dealers will receive the tube parts packages as shown. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect brake/fuel tubes and install clip 05705182 0.2 Hours Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8 Hours Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours Add the cost of the recall parts package(s) plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6812 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Tubes For Corrosion and Install Retaining Clip 1. With ignition switch in the off position, raise vehicle on a hoist. 2. Remove and discard the under body bracket and rubber isolator retaining the rear brake tubes, fuel vapor tube and fuel supply tube (Figure 1). 3. Carefully inspect all four tubes in the area that was covered by the rubber isolator as shown in figure 2. If any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed to section B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes with white powder or other residue/discoloration do not require replacement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6813 4. If no red corrosion is present on any of the four tubes, reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 5. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 7. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 8. Lower vehicle from hoist. B. Replace Corroded Tube(s) and Install Retaining Clip Note: Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes. 1. Lower vehicle from the hoist. 2. Remove air inlet tube, air cleaner housing and coolant over flow bottle. 3. Remove brake lamp fuse from the Power Distribution Center (PDC). 4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat. Note: Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding. 5. Disconnect the left rear and right rear brake tubes from the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles. Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled. 6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring. Note: To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer. 7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect. 8. Raise vehicle on hoist. 9. Remove the splash shield located at fuel tank sending unit and fuel filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6814 10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop. 11. Remove bolt retaining fuel filter and lower fuel filter. 12. Disconnect fuel tank sending unit wiring connector. 13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4). Caution: It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned. 14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4). Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur. 15. Disconnect rear brake tubes from all under body plastic clips. Note: Leave clips attached to body. Clips may break if removal is attempted. 16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5). Note: To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered. 17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube. 18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6815 19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect. 20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose. 21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose. Note: ABS wiring must be clipped to the top frame clip positions. 22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose. Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes. 23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position). 24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes. 25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3) Note: The two outboard bolts must be installed to assure the structural integrity of the frame rail. 26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3. 27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3). 28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3). 29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5). 30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m). 31. Attach rear end of vapor tube to the vapor hose at the fuel tank. 32. Attach fuel tank sending unit wiring connector. 33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m). 34. Install splash shield at fuel tank sending unit and fuel filter. 35. Lower vehicle from hoist. 36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations. Note: If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS). 37. Install the left rear and right rear brake tubes to the: ^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or; ^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m). 38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6816 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate. Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose. 39. Install coolant overflow bottle. 40. Install air cleaner housing and air inlet duct. 41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. 42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC. 43. Bleed the rear brakes. 44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist. 45. Road test vehicle to assure proper operation. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Safety Recall # 705 -- Brake/Fuel Tube Corrosion ^ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL) vehicles built through: ^ September 6, 1994 (MDH 090610) at the Belvidere Assembly Plant ("D" in the 11th VIN position) ^ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN position) ^ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may cause the tubes to leak due to corrosion perforation. To correct this condition, the rubber isolator must be removed and a clip installed to retain the four tubes to the crossmember. Also, all four tubes must be inspected at the isolator location, and any tube found with RED CORROSION must be replaced. Note that only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. ^ This notification will be implemented in phases. Owners of vehicles located in the following salt belt states (Recall # 7051) will be notified initially: Connecticut Michigan Pennsylvania Delaware Minnesota Rhode Island Illinois Missouri Vermont Indiana New Hampshire Virginia Iowa New Jersey Washington, D.C. Maine New York West Virginia Maryland Ohio Wisconsin Massachusetts Owners of vehicles located in the remaining non-salt belt states (Recall # 7052) will be notified about one month later. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Retainer Clip Packages to service 100% of those vehicles. In addition, enough of the tube packages will be distributed to service the referenced percentage of those vehicles as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 705 > Nov > 96 > Recall Brake/Fuel Tube Corrosion > Page 6817 Owner Letter SAFETY RECALL TO INSTALL A BRAKE/FUEL TUBE CLIP AND REPLACE YOUR VEHICLE'S BRAKE/FUEL TUBES IF NECESSARY Dear Neon Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 Dodge/Plymouth Neon vehicles. The problem is... The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube on your Neon (identified on the enclosed form), may cause the tubes to leak due to corrosion perforation. A brake fluid leak could result in increased stopping distance that may cause an accident without prior warning. A fuel leak could create the potential for a vehicle fire which could be hazardous to vehicle occupants. What Chrysler and your dealer will do... Chrysler will repair your Neon free of charge (parts and labor). To do this, your dealer will remove the rubber isolator and install a plastic clip to retain the four tubes to the vehicle. Also, all four tubes will be inspected at the isolator location, and any tube found with red corrosion will be replaced. The clip installation will take less than one-half hour to complete. An additional two hours may be required if any of the tubes need to be replaced. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > NHTSA94V034000 > Feb > 94 > Recall 94V034000: Brake Line Bracket Screw Failure Brake Hose/Line: All Technical Service Bulletins Recall 94V034000: Brake Line Bracket Screw Failure The rear brake hose mounting bracket screws can fail allowing the brake hoses to move out of position. The unrestrained hoses are then susceptible to damage which could result in brake fluid leakage. Brake fluid leakage will reduce the braking performance of the vehicle, extend stopping distances, and could result in an accident. The rear brake line hose bracket screws on these vehicles will be replaced. SYSTEM: BRAKES; HYDRAULIC; LINES; FITTINGS. VEHICLE DESCRIPTION: PASSENGER VEHICLES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OF NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 6822 Brake Hose/Line: Service Precautions WARNING: NEVER use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 6823 Brake Hose/Line: Testing and Inspection Steel tubing is used to transfer hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rust, damage or defective flared seats. The tubing is equipped with a double flare/inverted seat or ISO flare to ensure more positive seating in the fitting. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 6824 Brake Hose/Line: Service and Repair WARNING: Never use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure. Steel tubing is used to transfer hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rust, damage or defective flared seats. The tubing is equipped with a double flare/inverted seat or ISO flare to ensure more positive seating in the fitting. DOUBLE FLARE/INVERTED SEAT Cutting And Flaring Of Brake Fluid Tubing 1. Using the tool shown, or equivalent, cut off the damaged seat or damaged tubing. 2. Ream out any burrs or rough edges showing on inside edges of tubing. This will make the ends of the tubing square and ensure better seating on the flared end. Before flaring tubing, place a compression nut on tubing. 3. Open handles of flaring tool and rotate jaws of tool until mating jaws of tubing size are centered in the area between vertical posts. 4. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. 5. Place gauge on edge over end of tubing and push tubing through jaws until end of tubing contacts recessed notch of gauge matching size of tubing. 6. Squeeze handles of flaring tool and lock tubing in place. 7. Place proper size plug of gauge down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess in disc. 8. Lubricate taper of flaring or screw and screw in until plug gauge has seated in jaws of flaring tool. This action has started to invert the extended end of tubing. 9. Remove gauge and apply lubricant to tapered end of flaring screw and continue to screw down until tool is firmly seated in tubing. 10. Remove tubing from flaring tool and inspect the seat. If seat is cracked, cut off cracked end and repeat flaring operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Proportioning Valve - Pressure Adapter Tool Revision Brake Proportioning/Combination Valve: Technical Service Bulletins Proportioning Valve - Pressure Adapter Tool Revision NUMBER: 05-03-00 GROUP: Brakes DATE: April 14, 2000 SUBJECT: Proportioning Valve Brake Pressure Adapter Tool Revision MODELS: 1995-1999 (PL) Neon DISCUSSION: Figure 1 Diagnosing and testing the brake proportioning valves following the procedure in the appropriate Neon Service Manual calls for the use of the Brake Pressure Adapter Set 6805 and Brake Gauge Set C-4007-A. Alternate adapters from prior tool shipments should now be used on the Neon in place of the adapters provided in the Brake Pressure Adapter Set 6805. When the Neon Service Manual calls for Adapter 6805-3, use Adapter 8187-2 (Figure 1) which was shipped with the 1998 Concorde/Intrepid special tools in kit 8180CC or stored on panel 78. When the Neon Service Manual calls for Adapter 6805-4, use Adapter 6833-1 (Figure 1) which was shipped in the 1996 Minivan special tool kit and stored on panel 70. If you are unable to locate these adapters (6833-1 & 8187-2), they are available separately through Miller Special Tools (1-800-801-5420). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 6831 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes With 13 Inch Disc/Drum System Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. With 14 Inch Disc/Disc System Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. With 14 Inch Disc/Drum System Valve Tag Color [01] ............................................................................................................................ ........................................................................ Black Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.43 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 600-700 Footnotes: [1] Color tag located under boot of valve stem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6832 Brake Proportioning/Combination Valve: Description and Operation This system uses proportioning valves to balance front to rear braking by controlling, at a given ratio, the increase in rear brake system hydraulic pressure above a preset level. Under light pedal application, the proportioning valves allow full hydraulic pressure to be applied to the rear brakes. Fig 35 Type 3 Proportioning Valve Identification There are two proportioning valve assemblies used in each vehicle. Due to differences in thread size, each valve has a different part number. During any service procedures, identify valve assemblies by part number or color code. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6833 Brake Proportioning/Combination Valve: Testing and Inspection Fig 36 Type 3 Proportioning Valve Test Fittings The in-line proportioning valves used in this system require special pressure fittings set No. 6805, or equivalent, to test for proper valve function. The fittings are installed before and after the proportioning valve being tested to verify valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls. The pressure gauges used for testing the in-line proportioning valves on both non-ABS and ABS systems is Pressure Gauge Set No. C-4007-A, or equivalent. If a condition of premature wheel skid occurs on a vehicle, the proportioning valve should always be tested prior to being replaced as there are conditions other than a faulty proportioning valve that can cause premature wheel skid, such as worn, contaminated or improper brake linings. LESS ANTI-LOCK BRAKE SYSTEM Fig 37 Type 3 Proportioning Valve Location. Neon Less ABS Fig 38 Type 3 Proportioning Valve Location 1. Road test vehicle to determine which rear wheel exhibits premature wheel skid. Refer to the images to determine which proportioning valve needs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6834 to be tested. 2. Remove hydraulic brake line from proportioning valve to be tested, then remove valve from master cylinder outlet port. 3. Install Pressure Test Fitting Tool No. 6805-1 or 6805-2, or equivalent, depending on the thread size, into outlet port of master cylinder. 4. Install proportioning valve into pressure test fitting. 5. Install Pressure Test Fitting Tool No. 6805-3 or 6805-4, or equivalent, depending on the thread size, into outlet port of proportioning valve. 6. Connect brake hydraulic line onto pressure test fitting on proportioning valve. 7. Install Pressure Gauge Set Tool No. C-4007-A, or equivalent, into test fitting and bleed air from pressure gauge hose. 8. Apply pressure to brake pedal until reading on proportioning valve inlet test fitting is appropriate, then check the pressure reading on the outlet test fitting. If the pressure on the outlet test fitting is not within specifications. 9. Install proportioning valve into master cylinder body until O-ring is seated, then torque proportioning valve to 30 ft. lbs. 10. Install brake tube onto proportioning valve and torque tube nut to 145 inch lbs. 11. Bleed brake line as outlined under Hydraulic Brake System/Service and Repair/Brake System Bleed. WITH ANTI-LOCK BRAKE SYSTEM Fig 39 Type 3 Proportioning Valve Location Fig 40 Type 3 Proportioning Valve Location 1. Road test vehicle to determine which rear wheel exhibits premature wheel skid. Refer to the images above to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake line from proportioning valve to be tested, then remove valve from master cylinder outlet port. 3. Install Pressure Test Fitting Tool No. 6805-1 or 6805-2, or equivalent, depending on the thread size, into outlet port of master cylinder. 4. Install proportioning valve into pressure test fitting in master cylinder outlet port. 5. Install Pressure Test Fitting Tool No. 6805-3 or 6805-4, or equivalent, depending on the thread size, into outlet port of proportioning valve. 6. Connect brake hydraulic line onto pressure test fitting on proportioning valve. 7. Install Pressure Gauge Set Tool No. C-4007-A, or equivalent, into test fitting and bleed air from pressure gauge hose. 8. Apply pressure to brake pedal until reading on proportioning valve inlet test fitting is appropriate, then check the pressure reading on the outlet test fitting. If the pressure on the outlet test fitting is not within specifications, replace proportioning valve. 9. Install proportioning valve into master cylinder body until O-ring is seated, then torque proportioning valve to 30 ft. lbs. 10. Install brake tube onto proportioning valve and torque tube nut to 145 inch lbs. 11. Bleed brake line as outlined under Hydraulic Brake System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates Hydraulic Control Unit: Technical Service Bulletins Brake Master Cylinder - Manual Updates NO: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 SUBJECT: Service Manual Revision - Brake System Master cylinder MODELS: 1995 (PL) Neon DISCUSSION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6839 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6840 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Brake Master Cylinder - Manual Updates > Page 6841 This technical service bulletin contains revised service manual pages. The revisions are marked with **ASTERISKS**. Please insert the attached revised service manual pages in the appropriate Service Manual. MANUAL PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 5-67 Push Rod Lubricant 5-72 Push Rod Lubricant 5-86 Push Rod Lubricant NOTE: THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE SERVICE MANUAL PERMANENT AND LESS CUMBERSOME. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6842 Hydraulic Control Unit: Locations The Hydraulic Control Unit is located below the master cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6843 Hydraulic Control Unit: Diagrams Modulator Connector Modulator Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6844 Hydraulic Control Unit: Description and Operation The Hydraulic Control Unit (HCU) is located under the master cylinder. The HCU contains the following components for controlling brakes during ABS braking; four decay valves, four shuttle valves, two fluid sumps, a pump/motor and a relay box. Also attached to the HCU are rear brake proportioning valves and the six hydraulic tubes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6845 Hydraulic Control Unit: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL 1. Disconnect battery ground cable and isolate cable. 2. Disconnect brake fluid level sensor electrical connector at base of master cylinder. 3. Disconnect primary and secondary brake tubes from master cylinder. Install plugs into master cylinder brake tube outlets. 4. Use a suitable brake cleaner to clean area where master cylinder attaches to power booster. 5. Pump brake pedal until it is firm. This will pump down the vacuum inside the power booster and prevent the booster from sucking in any contamination when removing the master cylinder. 6. Remove master cylinder to power booster retaining nuts, then slide master cylinder straight out. 7. Disconnect 6-way electrical connector from Hydraulic Control Unit (HCU) wiring harness and 10-way electrical connector from HCU relay box. 8. Remove primary and secondary master cylinder brake tubes from HCU. 9. Remove remaining brake tubes from proportioning valves and HCU outlet ports. 10. Raise and support vehicle. 11. Remove two bolts attaching HCU mounting bracket to side of front of frame rail. 12. Lower vehicle and remove bolts attaching HCU mounting bracket to top of frame rail. 13. Remove HCU and mounting bracket as an assembly from vehicle. INSTALLATION 1. Install HCU and mounting bracket as an assembly, on left frame rail of vehicle, aligning tabs on mounting bracket with holes in frame rail. 2. Install and loosely tighten bolt attaching HCU mounting bracket to top of frame rail. 3. Raise and support vehicle. 4. Install two bolts attaching HCU mounting bracket to side of front frame rail. Torque bolts to 16 ft. lbs. 5. Lower vehicle and torque bolt attaching HCU mounting bracket to top of frame rail to 9 ft. lbs. 6. Install four chassis brake tubes to HCU proportioning valves and outlet ports, torque brake tube nuts to 12 ft. lbs. 7. Install primary and secondary brake tubes from master cylinder onto HCU, then hand tighten tube nuts. 8. Connect electrical connectors to HCU. Fig 61 Power Brake Booster Vacuum Seal Removal 9. Using a small screwdriver, carefully remove vacuum seal from front of power brake booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 10. Remove old vacuum seal from master cylinder, if seal came out of power brake vacuum booster when master cylinder was removed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Technical Service Bulletins > Page 6846 Fig 62 Power Brake Booster Vacuum Seal Installation 11. Lubricate master cylinder push rod with Mopar Silicone Dielectric Compound - NO Substitutes. Then install new vacuum seal onto master cylinder push rod as shown. 12. Position master cylinder on studs of power brake booster, aligning push rods of power brake booster and master cylinder. 13. Install two master cylinder mounting nuts and torque to 21 ft. lbs. 14. Connect primary and secondary tubes to master cylinder and HCU. Torque brake tube nuts at master cylinder to 12 ft. lbs. and torque brake tube nuts at HCU to 15 ft. lbs. 15. Connect brake fluid level sensor electrical connector. 16. Bleed brake system as described in Hydraulic System/Service and Repair/Brake System Bleed procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston Technical Service Bulletin # 687 Date: 960601 Recall - Master Cylinder Primary Piston No. 687 June, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 687 -- Master Cylinder Primary Piston Models: ^ 1995 and 1996 Model Year Dodge Stratus, Chrysler Cirrus and 1996 Model Year Plymouth Breeze (JA) Vehicles (With and Without ABS) ^ 1995 and 1996 Model Year Dodge/Plymouth Neon (PL) Vehicles Equipped With Four Wheel Disc Brakes Without ABS The brake master cylinder rear piston seal may leak and cause a partial brake system loss. To correct this condition, the master cylinder primary piston assembly must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70 or VIP. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Primary Piston Packages, Recall PN CBEA6871 for ABS equipped vehicles and CBGA6872 for NON-ABS equipped vehicles, to service about 25% of those vehicles. Each parts package contains the components as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6855 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Code Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6856 1. Inspect the front surface of the master cylinder for one of the following bottom codes as shown in figure 1 (the letter code is not important for this service): ^ ABS equipped JA vehicles (TWO master cylinder brake tubes) with a code of 3895; ^ NON-ABS equipped JA vehicles (FOUR master cylinder brake tubes) with a code of 3893; or ^ NON-ABS equipped PL vehicles (FOUR master cylinder brake tubes) with a code of 3815 If the master cylinder has one of the above four digit codes, replace the primary piston as instructed in Section B (verify that the vehicle has not already been repaired by using DIAL system function 70 or VIP). If the master cylinder has any other bottom code, no further action is required. B. Replace Master Cylinder Primary Piston 1. Clean master cylinder and attaching area of power brake booster with Mopar Glass Cleaner PN 4318014. 2. 2.4L engine equipped vehicles: Remove the air cleaner resonator/housing for greater access to master cylinder. 3. Speed control equipped vehicles: Remove mounting nuts and set speed control servo aside for greater access to master cylinder. 4. Disconnect wiring to master cylinder reservoir brake fluid level sensor. 5. Disconnect the primary and secondary brake tubes from master cylinder. Install provided plugs into master cylinder outlet ports and cap the brake tubes. Note: DO NOT drip brake fluid on painted surfaces as this may damage paint. 6. Remove the two nuts attaching the master cylinder to the brake booster. Slide the brake tube mounting bracket from the inboard master cylinder mounting stud and slide master cylinder off the brake booster mounting studs. 7. Drain brake fluid from the master cylinder reservoir. 8. Clamp master cylinder in a vice at the mounting flange area. Thoroughly clean master cylinder and reservoir with Mopar Glass Cleaner PN 4318014 and wipe with a clean cloth. Caution: DO NOT use this cleaner on any internal master cylinder components or on the master cylinder piston bore. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6857 9. ABS equipped vehicles only: Using a screw driver, pry away from the fluid level sensor and remove reservoir from master cylinder as shown in Figure 2. Be careful not to damage the fluid level switch and KEEP MASTER CYLINDER CLEAN AT ALL TIMES. 10. ABS equipped vehicles only: a. Remove and discard only the rear reservoir grommet and note which hole the primary piston retaining pin is in (Figure 3). b. Remove the master cylinder from the vice and turn the master cylinder upside down. Using the provided dowel rod, stroke the piston to allow the retaining pin to fall out, then remove the primary piston (Figure 4). Discard the old pin and piston. Note: If necessary, use a magnet while stroking the piston to remove the pin. Piston removal may require air pressure. Apply compressed air Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6858 (regulated to about 20 psi) to the primary outlet, while blocking the rear reservoir opening. Be sure to wear safety goggles. 11. NON-ABS equipped vehicles only: Using the supplied dowel rod1 stroke and hold the primary piston and remove the snap ring from the rear of the master cylinder, then remove the primary piston (Figure 5). Discard the old piston and snap ring. Caution: Be careful not to damage cylinder bore when using snap ring pliers. Note: Piston removal may require air pressure. Install the reservoir cap and apply compressed air (regulated to about 20 psi) to one primary outlet, while blocking the other primary outlet. Be sure to wear safety goggles. 12. With CLEAN HANDS, rinse the inside of the master cylinder and lubricate both of the seals on the new primary piston assembly with clean brake fluid conforming to DOT 3 specifications. Insert the new piston assembly spring end first. Note: ABS pistons must be installed with the piston slot in a vertical position to allow for piston pin installation (Figure 4). 13. ABS equipped vehicles only: a. Using supplied dowel rod, stroke and hold the primary piston approximately 3/4 inch. Insert new retaining pin into the same hole in master cylinder body that the original retaining pin was in (Figure 3). When inserted properly, the end of pin should be almost flush with master cylinder surface (Figure 6). b. Remove front reservoir grommet from the master cylinder body and discard. Verify that both primary and secondary piston pins are seated (end of pins are almost flush with surface as shown in figure 6). Lubricate two provided reservoir grommets with clean brake fluid and install grommets into the master cylinder body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6859 c. Install reservoir onto master cylinder body using a rocking motion (fluid level sensor must be on outboard side when installed in vehicle). There must be no reservoir-to-grommet gaps, or grommet-to-master cylinder body gaps. If gaps exist, the piston pins may not be fully inserted (Figure 6). Caution: Make sure piston pins are inserted properly and that the grommets do not contact the ends of either pin. Failure to insert pins will cause brake drag. 14. NON-ABS equipped vehicles only: Using the supplied dowel rod, stroke and hold the primary piston assembly beyond the snap ring groove in the master cylinder body and install provided snap ring (Figure 5). Caution: Make sure snap ring is fully seated in groove. Be careful not to damage cylinder bore when using snap ring pliers. 15. Attach Miller Special Tool # 6802 bleed tubes to primary and secondary outlets and position tubes so the outlets will be submerged in brake fluid when reservoir is filled. Fill master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. Bench bleed master cylinder by using the provided dowel rod. Slowly depress pistons with dowel rod1 then allow pistons to return to the fully released position. Repeat this step several times after no air bubbles are expelled from the bleed tubes. This will insure all air is bled from the master cylinder (Figure 7). Note: DO NOT install the master cylinder without following the above bench bleeding procedure. When this procedure is followed, it is not necessary to bleed the entire vehicle brake system. 16. Remove the bleed tubes from the master cylinder outlet ports. Verify that brake fluid drips from both the primary and secondary outlet ports. Plug outlet ports with the supplied plugs, top off reservoir with brake fluid and install reservoir cap. Note: If brake fluid does not drip from the primary and/or secondary outlet ports, the master cylinder must be disassembled and the appropriate compensation port cleaned. On ABS master cylinders, no fluid dripping from an outlet port may also be caused by a missing/damaged piston pin or damaged piston center valve. 17. Install master cylinder assembly onto power brake booster studs. Align brake booster push rod with hole in master cylinder primary piston, then seat master cylinder against booster. Slide brake tube support bracket onto inboard mounting stud. Torque two attaching nuts to 250 in-lbs (28 N.m). 18. Remove master cylinder and brake tube plugs and attach brake tubes to master cylinder. Torque tube nuts to 145 in-lbs. (17 N.m). 19. Attach wiring connector to reservoir brake fluid level sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6860 20. Verify proper brake warning lamp operation by removing the reservoir cap and using the provided dowel rod (make sure rod is clean) to push the float to the bottom of its travel (Figure 8). With the key in the ON position and the float at the bottom of its travel the warning light should be illuminated. Reinstall reservoir cap. 21. With engine off, pump brake pedal about 3-4 times until all vacuum in power brake booster is depleted. Apply light brake pedal pressure and hold for a minimum of 30 seconds. The brake pedal should remain firm. Apply heavy brake pedal pressure and hold for a minimum of 30 seconds. Again, the brake pedal should remain firm. If the brake pedal drops or is not firm during either of these tests, the master cylinder may either have a damaged piston assembly or it was not properly bled and must be repaired accordingly. 22. Speed control equipped vehicles: Install speed control servo and tighten nuts securely. 23. 2.4L engine equipped vehicles: Install air cleaner resonator/housing. 24. Verify that no brake fluid leaks exists and road test vehicle to assure proper brake operation. Owner Letter SAFETY RECALL To INSPECT AND REPAIR YOUR VEHICLE'S BRAKE MASTER CYLINDER Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 and 1996 Dodge Stratus, Dodge/Plymouth Neon, Chrysler Cirrus and 1996 Plymouth Breeze vehicles. The Problem is... The master cylinder rear piston seal on your vehicle (identified on the enclosed form), may leak and cause a partial brake system loss. The brake warning light will turn on to signal system impairment. If this warning is ignored, an increase in stopping distance could result in an accident. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect your brake master cylinder and if necessary, replace the primary piston and seal assembly. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6861 written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > NHTSA96V075000 > Apr > 96 > Recall 96V075000: Brake Master Cylinder Leak Brake Master Cylinder: Recalls Recall 96V075000: Brake Master Cylinder Leak THE BRAKE MASTER CYLINDER CAN LEAK BRAKE FLUID DUE TO A DAMAGED DOUBLE LIP REAR PISTON SEAL. BRAKE FLUID LEAKAGE CAN RESULT IN DIMINISHED EFFECTIVENESS OF ONE HALF OF THE SPLIT BRAKE SYSTEM. THE INSTRUMENT PANEL WARNING LIGHT(S) WILL SIGNAL SYSTEM IMPAIRMENT PRIOR TO PARTIAL BRAKE SYSTEM LOSS. DEALERS WILL REPLACE THE REAR BRAKE MASTER CYLINDER PISTON ASSEMBLY. SYSTEM: BRAKES; HYDRAULIC; MASTER BRAKE CYLINDER. INCLUDES NEON VEHICLES EQUIPPED WITH THE "ACR COMPETITION" PACKAGE ONLY. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder Technical Service Bulletin # 608 Date: 940601 Recall - ABS Brake Master Cylinder No.: 608 June, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 608 -- ABS Brake Master Cylinder Models: 1995 Dodge/Plymouth Neon (PL-Body) ABS Equipped Vehicles Built Through January 14, 1994 (MDH 01-14-17) Reference: January 21, 1994 Electronic Mail (DMAIL) Message on this subject. The referenced DMAIL message instructed dealers to perform the following repair. Notification letters are now being mailed to owners of involved vehicles for which the recall service has not yet been completed according to current records. The ABS brake master cylinder rear seal may allow air ingestion into the cylinder and cause spongy brake feel or partial brake system loss. To correct this condition, the build date code of the master cylinder must be inspected and all master cylinders having a date code of 3309 and earlier must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the incomplete involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 All involved vehicles were entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Our records indicate that most of the involved vehicles have been serviced as a result of the January 21, 1994 DMAIL Message. Therefore, no parts will be distributed initially to dealers. Dealers are requested to order ABS Brake Master Cylinder Packages, PN 4762628, only to support scheduled repairs. Each parts package contains the following components: Quantity Description Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6870 1 ABS Brake Master Cylinder 1 Seal, Power Brake Booster Vacuum Owner Notification and Service Scheduling All incomplete involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect the master cylinder date code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. If you pick up and deliver a customer's vehicle, provide a loaner, etc. submit a separate claim and use labor operation number 95234150 for up to $50 in the special service section of the claim. Parts Return Initially, a small number of master cylinders are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Date Code Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6871 1. The date code is the TOP code located on the front (forward) boss of the aluminum master cylinder, and consists of 4 numbers and a letter (the letter is not important for this service). The first number indicates the calendar year built and the next three numbers indicate the day of the year. Any master cylinders with a date code of 3309 or earlier must be replaced (Figure 1). 2. If the master cylinder date code is 3310 or later, no further action is required. If the date code is 3309 or earlier, replace the master cylinder as instructed in Section B. B. Replace Master Cylinder 1. With the engine off, pump the brake pedal until a firm pedal is achieved (4-5 strokes). CAUTION: Vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. 2. Remove vehicle wiring harness connector from brake fluid level sensor (Figure 2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6872 3. Disconnect the primary and secondary brake tubes from master cylinder housing (Figure 3). Install plugs at both open brake tube outlets. Note: Clean brake tube connections and master cylinder to booster area with a suitable brake cleaner before disconnecting tubes. 4. Remove the 2 nuts attaching the master cylinder to the power brake vacuum booster and slide the master cylinder straight out of the booster (Figure 4). 5. Remove the vacuum seal located in the front of the power brake vacuum booster by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal. Then pry seal out of the booster (Figure 5). Caution: Do NOT attempt to pry seal out of power brake vacuum booster by inserting a tool between the seal and the brake booster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6873 6. Clamp the provided master cylinder in a vise and attach Bleeding Tubes, Special Tool 6802 to the master cylinder (Figure 6). Position tubes so outlets of Bleeding Tubes will be below surface of brake fluid when reservoir is filled to the proper level. 7. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 8. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled (Figure 6). 9. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. Remove master cylinder from vise. Note: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled prior to installation. 10. Make sure brake booster vacuum seal on master cylinder push rod is positioned with notches on vacuum seal pointing toward master cylinder housing, and that seal is seated against master cylinder housing (Figure 7). Remove plastic protector from master cylinder push rod. 11. Align push rod on power brake vacuum booster with master cylinder push rod and install the master cylinder straight onto the power brake unit mounting studs (Figure 4). 12. Install master cylinder mounting nuts and torque to 250 in-lbs (28 N.m). 13. Remove plugs and connect brake tubes to master cylinder primary and secondary ports (Figure 3). Then torque all tube nuts to 145 in-lbs. (17 N.m). 14. Connect brake fluid level sensor wiring connector (Figure 2). 15. Top off master cylinder reservoir as necessary. Start engine and pump brake pedal firmly several times to assure of proper pedal travel and feel. Then check the system for leaks. Owner Letter SAFETY RECALL -- ABS Brake Master Cylinder Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6874 Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 model Dodge and Plymouth Neon vehicles equipped with the anti4ock brake system (ABS). The anti-lock brake master cylinder rear seal may allow air ingestion into the cylinder and cause spongy brake feel or partial brake system loss. This could result in an increase in stopping distance and cause an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. You may inspect the master cylinder date code yourself. Please refer to the instructions on the reverse side of this letter for details. If the date code on the master cylinder is 3310 or later, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If the date code is 3309 or earlier, the master cylinder must be replaced. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition your dealer will inspect the master cylinder date code and replace it if necessary. The inspection and master cylinder replacement (if necessary) will take about one-half hour to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer to schedule a service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. ABS Brake Master Cylinder Date Code Insp. Instructions 1. The ABS brake master cylinder is located under the hood, at the driver's side rear corner of the engine compartment. The master cylinder date code is the TOP code located on the front (forward) boss of the aluminum master cylinder, and consists of 4 numbers and a letter (the letter is not important for this service). The first number indicates the calendar year built and the next three numbers indicate the day of the year. A master cylinder having a date code of 3309 or earlier must be replaced (Figure 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6875 2. If the master cylinder date code is 3310 or later, no further action is required. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. If the date code is 3309 or earlier, make an appointment with your dealer to have the master cylinder replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls: > NHTSA94V026000 > Jan > 94 > Recall 94V026000: ABS Master Cylinder Defect Brake Master Cylinder: Recalls Recall 94V026000: ABS Master Cylinder Defect THE ABS BRAKE MASTER CYLINDER REAR SEAL ALLOWS AIR TO ENTER THE BRAKE SYSTEM, CAUSING SPONGY BRAKES OR PARTIAL BRAKE SYSTEM LOSS. AIR ENTERING THE BRAKE SYSTEM CAUSED EXTENDED STOPPING DISTANCE OR PARTIAL LOSS OF BRAKES WHICH MAY RESULT IN AN ACCIDENT. MASTER CYLINDERS WILL BE INSPECTED FOR THE SUSPECT BUILD DATE CODE RANGE AND WILL BE REPLACED IF NECESSARY. SYSTEM: BRAKES; HYDRAULIC; ANTI-SKID SYSTEM. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston Technical Service Bulletin # 687 Date: 960601 Recall - Master Cylinder Primary Piston No. 687 June, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 687 -- Master Cylinder Primary Piston Models: ^ 1995 and 1996 Model Year Dodge Stratus, Chrysler Cirrus and 1996 Model Year Plymouth Breeze (JA) Vehicles (With and Without ABS) ^ 1995 and 1996 Model Year Dodge/Plymouth Neon (PL) Vehicles Equipped With Four Wheel Disc Brakes Without ABS The brake master cylinder rear piston seal may leak and cause a partial brake system loss. To correct this condition, the master cylinder primary piston assembly must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70 or VIP. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Primary Piston Packages, Recall PN CBEA6871 for ABS equipped vehicles and CBGA6872 for NON-ABS equipped vehicles, to service about 25% of those vehicles. Each parts package contains the components as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6885 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Code Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6886 1. Inspect the front surface of the master cylinder for one of the following bottom codes as shown in figure 1 (the letter code is not important for this service): ^ ABS equipped JA vehicles (TWO master cylinder brake tubes) with a code of 3895; ^ NON-ABS equipped JA vehicles (FOUR master cylinder brake tubes) with a code of 3893; or ^ NON-ABS equipped PL vehicles (FOUR master cylinder brake tubes) with a code of 3815 If the master cylinder has one of the above four digit codes, replace the primary piston as instructed in Section B (verify that the vehicle has not already been repaired by using DIAL system function 70 or VIP). If the master cylinder has any other bottom code, no further action is required. B. Replace Master Cylinder Primary Piston 1. Clean master cylinder and attaching area of power brake booster with Mopar Glass Cleaner PN 4318014. 2. 2.4L engine equipped vehicles: Remove the air cleaner resonator/housing for greater access to master cylinder. 3. Speed control equipped vehicles: Remove mounting nuts and set speed control servo aside for greater access to master cylinder. 4. Disconnect wiring to master cylinder reservoir brake fluid level sensor. 5. Disconnect the primary and secondary brake tubes from master cylinder. Install provided plugs into master cylinder outlet ports and cap the brake tubes. Note: DO NOT drip brake fluid on painted surfaces as this may damage paint. 6. Remove the two nuts attaching the master cylinder to the brake booster. Slide the brake tube mounting bracket from the inboard master cylinder mounting stud and slide master cylinder off the brake booster mounting studs. 7. Drain brake fluid from the master cylinder reservoir. 8. Clamp master cylinder in a vice at the mounting flange area. Thoroughly clean master cylinder and reservoir with Mopar Glass Cleaner PN 4318014 and wipe with a clean cloth. Caution: DO NOT use this cleaner on any internal master cylinder components or on the master cylinder piston bore. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6887 9. ABS equipped vehicles only: Using a screw driver, pry away from the fluid level sensor and remove reservoir from master cylinder as shown in Figure 2. Be careful not to damage the fluid level switch and KEEP MASTER CYLINDER CLEAN AT ALL TIMES. 10. ABS equipped vehicles only: a. Remove and discard only the rear reservoir grommet and note which hole the primary piston retaining pin is in (Figure 3). b. Remove the master cylinder from the vice and turn the master cylinder upside down. Using the provided dowel rod, stroke the piston to allow the retaining pin to fall out, then remove the primary piston (Figure 4). Discard the old pin and piston. Note: If necessary, use a magnet while stroking the piston to remove the pin. Piston removal may require air pressure. Apply compressed air Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6888 (regulated to about 20 psi) to the primary outlet, while blocking the rear reservoir opening. Be sure to wear safety goggles. 11. NON-ABS equipped vehicles only: Using the supplied dowel rod1 stroke and hold the primary piston and remove the snap ring from the rear of the master cylinder, then remove the primary piston (Figure 5). Discard the old piston and snap ring. Caution: Be careful not to damage cylinder bore when using snap ring pliers. Note: Piston removal may require air pressure. Install the reservoir cap and apply compressed air (regulated to about 20 psi) to one primary outlet, while blocking the other primary outlet. Be sure to wear safety goggles. 12. With CLEAN HANDS, rinse the inside of the master cylinder and lubricate both of the seals on the new primary piston assembly with clean brake fluid conforming to DOT 3 specifications. Insert the new piston assembly spring end first. Note: ABS pistons must be installed with the piston slot in a vertical position to allow for piston pin installation (Figure 4). 13. ABS equipped vehicles only: a. Using supplied dowel rod, stroke and hold the primary piston approximately 3/4 inch. Insert new retaining pin into the same hole in master cylinder body that the original retaining pin was in (Figure 3). When inserted properly, the end of pin should be almost flush with master cylinder surface (Figure 6). b. Remove front reservoir grommet from the master cylinder body and discard. Verify that both primary and secondary piston pins are seated (end of pins are almost flush with surface as shown in figure 6). Lubricate two provided reservoir grommets with clean brake fluid and install grommets into the master cylinder body. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6889 c. Install reservoir onto master cylinder body using a rocking motion (fluid level sensor must be on outboard side when installed in vehicle). There must be no reservoir-to-grommet gaps, or grommet-to-master cylinder body gaps. If gaps exist, the piston pins may not be fully inserted (Figure 6). Caution: Make sure piston pins are inserted properly and that the grommets do not contact the ends of either pin. Failure to insert pins will cause brake drag. 14. NON-ABS equipped vehicles only: Using the supplied dowel rod, stroke and hold the primary piston assembly beyond the snap ring groove in the master cylinder body and install provided snap ring (Figure 5). Caution: Make sure snap ring is fully seated in groove. Be careful not to damage cylinder bore when using snap ring pliers. 15. Attach Miller Special Tool # 6802 bleed tubes to primary and secondary outlets and position tubes so the outlets will be submerged in brake fluid when reservoir is filled. Fill master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. Bench bleed master cylinder by using the provided dowel rod. Slowly depress pistons with dowel rod1 then allow pistons to return to the fully released position. Repeat this step several times after no air bubbles are expelled from the bleed tubes. This will insure all air is bled from the master cylinder (Figure 7). Note: DO NOT install the master cylinder without following the above bench bleeding procedure. When this procedure is followed, it is not necessary to bleed the entire vehicle brake system. 16. Remove the bleed tubes from the master cylinder outlet ports. Verify that brake fluid drips from both the primary and secondary outlet ports. Plug outlet ports with the supplied plugs, top off reservoir with brake fluid and install reservoir cap. Note: If brake fluid does not drip from the primary and/or secondary outlet ports, the master cylinder must be disassembled and the appropriate compensation port cleaned. On ABS master cylinders, no fluid dripping from an outlet port may also be caused by a missing/damaged piston pin or damaged piston center valve. 17. Install master cylinder assembly onto power brake booster studs. Align brake booster push rod with hole in master cylinder primary piston, then seat master cylinder against booster. Slide brake tube support bracket onto inboard mounting stud. Torque two attaching nuts to 250 in-lbs (28 N.m). 18. Remove master cylinder and brake tube plugs and attach brake tubes to master cylinder. Torque tube nuts to 145 in-lbs. (17 N.m). 19. Attach wiring connector to reservoir brake fluid level sensor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6890 20. Verify proper brake warning lamp operation by removing the reservoir cap and using the provided dowel rod (make sure rod is clean) to push the float to the bottom of its travel (Figure 8). With the key in the ON position and the float at the bottom of its travel the warning light should be illuminated. Reinstall reservoir cap. 21. With engine off, pump brake pedal about 3-4 times until all vacuum in power brake booster is depleted. Apply light brake pedal pressure and hold for a minimum of 30 seconds. The brake pedal should remain firm. Apply heavy brake pedal pressure and hold for a minimum of 30 seconds. Again, the brake pedal should remain firm. If the brake pedal drops or is not firm during either of these tests, the master cylinder may either have a damaged piston assembly or it was not properly bled and must be repaired accordingly. 22. Speed control equipped vehicles: Install speed control servo and tighten nuts securely. 23. 2.4L engine equipped vehicles: Install air cleaner resonator/housing. 24. Verify that no brake fluid leaks exists and road test vehicle to assure proper brake operation. Owner Letter SAFETY RECALL To INSPECT AND REPAIR YOUR VEHICLE'S BRAKE MASTER CYLINDER Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 and 1996 Dodge Stratus, Dodge/Plymouth Neon, Chrysler Cirrus and 1996 Plymouth Breeze vehicles. The Problem is... The master cylinder rear piston seal on your vehicle (identified on the enclosed form), may leak and cause a partial brake system loss. The brake warning light will turn on to signal system impairment. If this warning is ignored, an increase in stopping distance could result in an accident. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect your brake master cylinder and if necessary, replace the primary piston and seal assembly. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 6891 written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA96V075000 > Apr > 96 > Recall 96V075000: Brake Master Cylinder Leak Brake Master Cylinder: All Technical Service Bulletins Recall 96V075000: Brake Master Cylinder Leak THE BRAKE MASTER CYLINDER CAN LEAK BRAKE FLUID DUE TO A DAMAGED DOUBLE LIP REAR PISTON SEAL. BRAKE FLUID LEAKAGE CAN RESULT IN DIMINISHED EFFECTIVENESS OF ONE HALF OF THE SPLIT BRAKE SYSTEM. THE INSTRUMENT PANEL WARNING LIGHT(S) WILL SIGNAL SYSTEM IMPAIRMENT PRIOR TO PARTIAL BRAKE SYSTEM LOSS. DEALERS WILL REPLACE THE REAR BRAKE MASTER CYLINDER PISTON ASSEMBLY. SYSTEM: BRAKES; HYDRAULIC; MASTER BRAKE CYLINDER. INCLUDES NEON VEHICLES EQUIPPED WITH THE "ACR COMPETITION" PACKAGE ONLY. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder Technical Service Bulletin # 608 Date: 940601 Recall - ABS Brake Master Cylinder No.: 608 June, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 608 -- ABS Brake Master Cylinder Models: 1995 Dodge/Plymouth Neon (PL-Body) ABS Equipped Vehicles Built Through January 14, 1994 (MDH 01-14-17) Reference: January 21, 1994 Electronic Mail (DMAIL) Message on this subject. The referenced DMAIL message instructed dealers to perform the following repair. Notification letters are now being mailed to owners of involved vehicles for which the recall service has not yet been completed according to current records. The ABS brake master cylinder rear seal may allow air ingestion into the cylinder and cause spongy brake feel or partial brake system loss. To correct this condition, the build date code of the master cylinder must be inspected and all master cylinders having a date code of 3309 and earlier must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the incomplete involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 All involved vehicles were entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Our records indicate that most of the involved vehicles have been serviced as a result of the January 21, 1994 DMAIL Message. Therefore, no parts will be distributed initially to dealers. Dealers are requested to order ABS Brake Master Cylinder Packages, PN 4762628, only to support scheduled repairs. Each parts package contains the following components: Quantity Description Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6900 1 ABS Brake Master Cylinder 1 Seal, Power Brake Booster Vacuum Owner Notification and Service Scheduling All incomplete involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect the master cylinder date code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. If you pick up and deliver a customer's vehicle, provide a loaner, etc. submit a separate claim and use labor operation number 95234150 for up to $50 in the special service section of the claim. Parts Return Initially, a small number of master cylinders are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Date Code Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6901 1. The date code is the TOP code located on the front (forward) boss of the aluminum master cylinder, and consists of 4 numbers and a letter (the letter is not important for this service). The first number indicates the calendar year built and the next three numbers indicate the day of the year. Any master cylinders with a date code of 3309 or earlier must be replaced (Figure 1). 2. If the master cylinder date code is 3310 or later, no further action is required. If the date code is 3309 or earlier, replace the master cylinder as instructed in Section B. B. Replace Master Cylinder 1. With the engine off, pump the brake pedal until a firm pedal is achieved (4-5 strokes). CAUTION: Vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. 2. Remove vehicle wiring harness connector from brake fluid level sensor (Figure 2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6902 3. Disconnect the primary and secondary brake tubes from master cylinder housing (Figure 3). Install plugs at both open brake tube outlets. Note: Clean brake tube connections and master cylinder to booster area with a suitable brake cleaner before disconnecting tubes. 4. Remove the 2 nuts attaching the master cylinder to the power brake vacuum booster and slide the master cylinder straight out of the booster (Figure 4). 5. Remove the vacuum seal located in the front of the power brake vacuum booster by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal. Then pry seal out of the booster (Figure 5). Caution: Do NOT attempt to pry seal out of power brake vacuum booster by inserting a tool between the seal and the brake booster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6903 6. Clamp the provided master cylinder in a vise and attach Bleeding Tubes, Special Tool 6802 to the master cylinder (Figure 6). Position tubes so outlets of Bleeding Tubes will be below surface of brake fluid when reservoir is filled to the proper level. 7. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 8. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled (Figure 6). 9. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. Remove master cylinder from vise. Note: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled prior to installation. 10. Make sure brake booster vacuum seal on master cylinder push rod is positioned with notches on vacuum seal pointing toward master cylinder housing, and that seal is seated against master cylinder housing (Figure 7). Remove plastic protector from master cylinder push rod. 11. Align push rod on power brake vacuum booster with master cylinder push rod and install the master cylinder straight onto the power brake unit mounting studs (Figure 4). 12. Install master cylinder mounting nuts and torque to 250 in-lbs (28 N.m). 13. Remove plugs and connect brake tubes to master cylinder primary and secondary ports (Figure 3). Then torque all tube nuts to 145 in-lbs. (17 N.m). 14. Connect brake fluid level sensor wiring connector (Figure 2). 15. Top off master cylinder reservoir as necessary. Start engine and pump brake pedal firmly several times to assure of proper pedal travel and feel. Then check the system for leaks. Owner Letter SAFETY RECALL -- ABS Brake Master Cylinder Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6904 Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 model Dodge and Plymouth Neon vehicles equipped with the anti4ock brake system (ABS). The anti-lock brake master cylinder rear seal may allow air ingestion into the cylinder and cause spongy brake feel or partial brake system loss. This could result in an increase in stopping distance and cause an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. You may inspect the master cylinder date code yourself. Please refer to the instructions on the reverse side of this letter for details. If the date code on the master cylinder is 3310 or later, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If the date code is 3309 or earlier, the master cylinder must be replaced. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition your dealer will inspect the master cylinder date code and replace it if necessary. The inspection and master cylinder replacement (if necessary) will take about one-half hour to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer to schedule a service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. ABS Brake Master Cylinder Date Code Insp. Instructions 1. The ABS brake master cylinder is located under the hood, at the driver's side rear corner of the engine compartment. The master cylinder date code is the TOP code located on the front (forward) boss of the aluminum master cylinder, and consists of 4 numbers and a letter (the letter is not important for this service). The first number indicates the calendar year built and the next three numbers indicate the day of the year. A master cylinder having a date code of 3309 or earlier must be replaced (Figure 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 608 > Jun > 94 > Recall - ABS Brake Master Cylinder > Page 6905 2. If the master cylinder date code is 3310 or later, no further action is required. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. If the date code is 3309 or earlier, make an appointment with your dealer to have the master cylinder replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates Brake Master Cylinder: All Technical Service Bulletins Brake Master Cylinder - Manual Updates NO: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 SUBJECT: Service Manual Revision - Brake System Master cylinder MODELS: 1995 (PL) Neon DISCUSSION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6910 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6911 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6912 This technical service bulletin contains revised service manual pages. The revisions are marked with **ASTERISKS**. Please insert the attached revised service manual pages in the appropriate Service Manual. MANUAL PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 5-67 Push Rod Lubricant 5-72 Push Rod Lubricant 5-86 Push Rod Lubricant NOTE: THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE SERVICE MANUAL PERMANENT AND LESS CUMBERSOME. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision Brake Master Cylinder: All Technical Service Bulletins Brakes - Master Cylinder Push Rod Lubing Revision NUMBER: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Push Rod Lubricant Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6917 5-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6918 5-72 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6919 5-86 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA94V026000 > Jan > 94 > Recall 94V026000: ABS Master Cylinder Defect Brake Master Cylinder: All Technical Service Bulletins Recall 94V026000: ABS Master Cylinder Defect THE ABS BRAKE MASTER CYLINDER REAR SEAL ALLOWS AIR TO ENTER THE BRAKE SYSTEM, CAUSING SPONGY BRAKES OR PARTIAL BRAKE SYSTEM LOSS. AIR ENTERING THE BRAKE SYSTEM CAUSED EXTENDED STOPPING DISTANCE OR PARTIAL LOSS OF BRAKES WHICH MAY RESULT IN AN ACCIDENT. MASTER CYLINDERS WILL BE INSPECTED FOR THE SUSPECT BUILD DATE CODE RANGE AND WILL BE REPLACED IF NECESSARY. SYSTEM: BRAKES; HYDRAULIC; ANTI-SKID SYSTEM. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT CHRYSLER SERVICE CENTER AT 1-800-992-1997. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates Brake Master Cylinder: All Technical Service Bulletins Brake Master Cylinder - Manual Updates NO: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 SUBJECT: Service Manual Revision - Brake System Master cylinder MODELS: 1995 (PL) Neon DISCUSSION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6929 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6930 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 050794 > Apr > 94 > Brake Master Cylinder - Manual Updates > Page 6931 This technical service bulletin contains revised service manual pages. The revisions are marked with **ASTERISKS**. Please insert the attached revised service manual pages in the appropriate Service Manual. MANUAL PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 5-67 Push Rod Lubricant 5-72 Push Rod Lubricant 5-86 Push Rod Lubricant NOTE: THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE SERVICE MANUAL PERMANENT AND LESS CUMBERSOME. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision Brake Master Cylinder: All Technical Service Bulletins Brakes - Master Cylinder Push Rod Lubing Revision NUMBER: 05-07-94 GROUP: Brakes DATE: Apr. 22, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Push Rod Lubricant Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6936 5-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6937 5-72 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Master Cylinder: > 05-07-94 > Apr > 94 > Brakes - Master Cylinder Push Rod Lubing Revision > Page 6938 5-86 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 6939 Brake Master Cylinder: Specifications Master Cylinder Bore Dia. Inch ............................................................................................................ ........................................................................ 0.875 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes This system uses a modified master cylinder and power brake booster assembly. The master cylinder primary and secondary outputs go directly to the Hydraulic Control Unit (HCU). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 6942 Brake Master Cylinder: Description and Operation Without Antilock Brakes This type of master cylinder, utilizes screw-in proportioning valves at the master cylinder instead of a combination valve. With this new design, the chassis brake tubes connect directly from the master cylinder to the brake flex hose. Vehicles not equipped with Antilock Brake System (ABS) use a standard compensating port design, while vehicles equipped with ABS use a center valve design. Fig 4 Type 3 Master Cylinder. Less ABS In addition, the non-ABS master cylinders are a four outlet design with two screw-in proportioning valves attached directly to the inboard side of the master cylinder housing. Fig 5 Type 3 Master Cylinder. With ABS The ABS master cylinders are a two outlet design with the screw-in proportioning valves attached to the ABS Hydraulic Control Unit (HCU). Vehicles equipped with rear drum brakes use a master cylinder with a 21 mm bore, while vehicles equipped with rear disc brakes use a 7/8 inch bore master cylinder. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir assembly is made of polypropylene plastic. The only serviceable component on both master cylinders are the reservoir and the sealing grommets. Neither of the master cylinder assemblies can be serviced, and must be replaced as an assembly. On non-ABS master cylinders, the primary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 6943 Fig 6 Type 3 Primary And Secondary Output Ports. Less ABS The secondary outlet ports supply hydraulic pressure to the right front and left rear brakes. Fig 7 Type 3 Primary And Secondary Output Ports. With ABS On ABS master cylinders, the primary outlet ports supply hydraulic pressure to the right front and left rear brakes. the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Notes and Precautions Combination valves containing brake warning or pressure differential type valves are self-centering. They will reset after hydraulic system pressure is equalized, and by doing the following: Upon completion of bleeding the hydraulic system, depress the brake pedal with moderate force. The brake warning lamp will turn off when the switch is re-centered. Bench Bleeding When replacing or overhauling a master cylinder, it is advisable to bleed it before installing it on the car. Bleeding Tubes Attached To Master Cylinder Without ABS Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6946 Bleeding Master Cylinder PROCEDURE 1. Clamp the master cylinder in a vise. Attach bleeding tubes, Special Tool 6802, or equivalent to the master cylinder outlet ports. Position bleeding tubes so the outlets of the bleeding tubes will be below the surface of the brake fluid when reservoir is filled to proper level. 2. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 3. Using a wooden dowel. Depress push rod slowly, and then allow pistons to return to the released position. Continue to repeat this step several times after no more air bubbles are expelled from bleed tubes to ensure all air is bled from the master cylinder. 4. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. 5. Remove master cylinder from vise and install master cylinder into vehicle. 6. Bleed the entire hydraulic system. Manual Bleeding Master cylinders may be bled manually or by pressure bleeding. It is recommended that the master cylinder be bled before bleeding the wheel cylinders and calipers. CAUTION: Use the specified brake fluid. Don't use a mixture of the specified brake fluid and another non-specified fluid. Specified brake fluid: MOPAR DOT 3 or DOT 4 MANUAL BLEEDING 1. Ensure master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. 2. Position a drain pan under the master cylinder. 3. Have an assistant depress the brake pedal with a slow even pressure and hold it. Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 4. Loosen the brake lines, or bleeder valves if equipped, at the master cylinder. Watch for air bubbles in the fluid and listen for air escaping from the system. While bleeding the system, recheck brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 5. With brake pedal still depressed, tighten the brake lines or bleeder valves. 6. Bleed the master cylinder until all air is removed. Upon completion of bleeding, proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Ensure brake pedal is firm, and braking operation is proper. Pressure Bleeding Master cylinders may be bled manually or by pressure bleeding. It is recommended that the master cylinder be bled before bleeding the wheel cylinders and calipers. PRESSURE BLEEDING 1. Ensure master cylinder reservoir is full. Add suitable brake fluid as needed. 2. Install pressure bleeder according to manufacturer specifications. 3. Position a drain pan under the master cylinder. 4. Loosen brake lines, or bleeder valves if equipped, at the master cylinder. Watch for air bubbles in the fluid and listen for air escaping from the system. 5. Retighten brake lines or bleeder valves. 6. Bleed the master cylinder until all air is removed. Upon completion of bleeding, proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Ensure brake pedal is firm, and braking operation is proper. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6947 Brake Master Cylinder: Service and Repair Master Cylinder Replacement The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL When replacing master cylinder on models equipped with ABS, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done by pumping the brake pedal until it is firm, with the ignition off. 1. On models equipped with ABS, ensure engine is not running and brake pedal has been pumped until firm. 2. On all models, remove wiring harness connector from brake fluid level sensor mounted on fluid reservoir. 3. Disconnect the primary and secondary brake tubes from master cylinder housing. Install suitable plugs at all open brake tube outlets on master cylinder assembly. 4. On models equipped with ABS, clean area where master cylinder attaches to power brake vacuum booster using a suitable brake cleaner. 5. On all models, remove nuts attaching master cylinder to power brake vacuum booster. 6. Slide master cylinder forward out of power brake vacuum booster. Fig 18 Type 3 Vacuum Seal Removed. Neon Models Equipped With ABS 7. On models equipped with ABS, the vacuum seal in the front of the power brake vacuum booster must be replaced. Remove vacuum seal in front of power brake vacuum booster by carefully inserting a suitable, small, screwdriver between master cylinder push rod and vacuum seal and prying seal out of booster. Do not attempt to pry seal out by inserting screwdriver between seal and booster. INSTALLATION 1. On models equipped with ABS, install new vacuum seal as follows: a. Lubricate master cylinder push rod using Mopar Silicone Dielectric Compound - NO Substitutes. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6948 Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS b. Slide vacuum seal onto master cylinder push rod with notches on seal pointing toward and seated against master cylinder housing. 2. On all models, slide master cylinder assembly into power brake vacuum booster and position on mounting studs. 3. Install mounting nuts and torque to 250 in. lbs. 4. Connect brake tubes to master cylinder primary and secondary ports and torque tube nuts to 145 in. lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6949 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul When disassembling the master cylinder, note the position of all parts as they are removed for proper installation. When disassembled, wash all parts in denatured alcohol or clean brake fluid only. Use an air hose to blow out all passages, orifices and valve holes. Air dry and place parts on clean paper or lint-free cloth. Inspect master cylinder bore for scoring, rust, pitting or etching. Any of these conditions will require replacement of the housing. Never hone the bore of the master cylinder as this will remove the anodized surface. Inspect master cylinder pistons for scoring, pitting or distortion. Replace piston if any of these conditions exist. If either the master cylinder housing or piston is replaced, clean the new parts with denatured alcohol or clean brake fluid, and blow out all passages with air hose. Examine reservoirs for foreign matter and check all passages for restrictions. If there is any indication of contamination or evidence of corrosion, service the hydraulic system as needed, and flush the entire system as described under Hydraulic System / Service and Repair / Brake System Bleed. When reassembling the master cylinder, use all parts contained in the repair kit. Dip all component parts in clean brake fluid, and place them on a clean surface. To prevent faulty operation, when installing seals inspect through side outlet of the dual master cylinder housing to make certain cup lips do not hang up on edge of hole or turn back. A piece of 3/16 inch rod with an end rounded off will be helpful in guiding cups past the hole. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6950 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement REMOVAL 1. Clean master cylinder housing and brake fluid reservoir. 2. Remove reservoir cap and remove as much brake fluid as possible using suitable syringe or similar tool. Removing Fluid Reservoir From Master Cylinder 3. Rock reservoir from side to side while pulling upward to remove from master cylinder housing. Do not pry off using a tool as damage to reservoir may result. 4. Remove reservoir grommets from master cylinder housing. INSTALLATION 1. Install new reservoir grommets in master cylinder housing. 2. Lubricate reservoir mounting area with fresh, clean brake fluid. 3. Install reservoir by pushing downward and rocking from side to side. Ensure reservoir is fully seated. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: Customer Interest Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 6959 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 6965 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cylinder: > 211194 > May > 94 > M/T Gear Shift Lever/Knob Vibration In 3RD Gear Synchronizer Ring: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cylinder: > 211194 > May > 94 > M/T Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6971 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cylinder: > 211194 > May > 94 > M/T Gear Shift Lever/Knob Vibration In 3RD Gear > Page 6977 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6978 Wheel Cylinder: Specifications Bearing Retainer Bolts 160 ft.lb Brake Line Fittings 12 ft.lb Support Plate To Rear Axle 85 ft.lb Wheel Cylinder Bleed Screws 6 ft.lb Wheel Cylinder To Backing Plate 6 ft.lb Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel, drum and brake shoes. 2. Loosen brake line fitting at wheel cylinder. Do not pull metal line away from cylinder. 3. Remove screws holding cylinder to backing plate. 4. Separate wheel cylinder from brake line and backing plate by pulling the cylinder outward and away from backing plate. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Position wheel cylinder to backing plate. Install brake line to cylinder and start connecting fitting. 3. Secure wheel cylinder to backing plate, then complete tightening of brake line fitting. 4. Install brake shoes, drum and wheel. 5. Bleed system as outlined previously, and adjust brakes. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 6981 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Note position of all parts as they are removed for proper installation. DISASSEMBLE Fig 28 Disassembled View Of Typical Wheel Cylinder 1. Remove boots, pistons, cups and spring from wheel cylinder. 2. Wipe cylinder walls with denatured alcohol or clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the bore diameter is not increased more than 0.005 inch. Replace as necessary. 4. Check pistons for wear or damage. Replace as necessary. ASSEMBLE 1. Before assembling, wash hands with soap and water so as not to contaminate rubber parts. 2. Use all parts contained in repair kit. Lubricate cylinder wall and rubber cups with brake fluid. 3. Properly install spring, cups, pistons and boots in housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal Parking Brake Cable: Service and Repair Cable Removal NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. PROCEDURE Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 1. Remove screws attaching rear of center console assembly to floor pan of vehicle. Attaching Screws At Front Of Center Console 2. Remove the 2 screws located in cup holders attaching front of center console to console bracket. 3. Raise park brake lever as high as it will go for the clearance required to remove the center console. 4. Remove center console assembly from vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6988 WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. 5. Lower park brake lever handle. Locking Pin Installed In Park Brake Lever 6. Grasp park lever output cable by hand and pull rearward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Park Brake Cables At Equalizer 7. Remove rear park brake cables from the park brake cable equalizer. 8. Remove rear seat cushion from vehicle. Rear Door Sill Scuff Plates Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6989 9. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 10. Fold rear carpeting forward to expose park brake cables. Compressing Park Brake Cable Retaining Tabs 11. Install the box end of a 1/2 in. wrench over the park brake cable retainer as indicated. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 12. Raise vehicle on jackstands or centered on a frame contact type hoist. 13. Remove rear wheel and tire assembly. Rear Brake Drum Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6990 Rear Brake Rotor 14. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub/Bearing Dust Cap Removal 15. Remove dust cap from rear hub/ bearing assembly. Hub/Bearing Assembly Retaining Nut 16. Remove hub/bearing assembly retaining nut. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6991 Hub/Bearing Removal From Spindle (Drum Brakes Shown) 17. Remove the rear hub/bearing assembly from the rear spindle. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 18. On vehicles equipped with rear drum brakes, remove park brake cable from park brake actuating lever. Then remove the actuating spring between brake shoe adjustment lever and brake shoe assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6992 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 19. On vehicles equipped with rear disc brakes, remove brake shoe assemblies from rear disc brake adapter. Then remove parking brake actuating lever from the park brake cable. Park Brake Cable Removal From Brake Support Plate 20. On vehicles equipped with rear drum brakes, remove park brake cable from rear brake support plate. Park brake cable is removed from brake support plate using a 1/2 in. wrench as shown above to compress locking tabs on park brake cable retainer. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6993 Park Brake Cable Removal From Disc Brake Adapter 21. On vehicles equipped with rear disc brakes, remove park brake cable from rear disc brake adapter. Park brake cable is removed from disc brake adapter using a screwdriver as shown to compress locking tabs on park brake cable retainer. Park Brake Cable Routing Bracket 22. Remove park brake cable routing bracket from vehicle frame rail. Park Brake Cable Seal At Floor Pan 23. Remove park brake cable and sealing grommet from floor pan of vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6994 Parking Brake Cable: Service and Repair Cable Installation PROCEDURE 1. Install park brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure proper seal. 2. Install park brake cable into brake support plate or rear disc brake adapter. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in support plate or adapter. Park Brake Cable Routing Bracket 3. Install park brake cable routing bracket on frame rail. Install and securely tighten routing bracket attaching bolt. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 4. On vehicles equipped with rear drum brakes, install park brake cable on park brake cable actuating lever. Then install actuating spring between brake shoe assembly and brake adjustment lever. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6995 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 5. On vehicles equipped with rear disc brakes, install park brake shoes actuator lever on park brake cable. Then install park brake shoe assemblies on disc brake adapter. 6. Install the hub/bearing assembly on the rear spindle. Then install A NEW rear hub/bearing assembly retaining nut. Torque hub/bearing assembly retaining nut to 217 Nm (160 ft. lbs.). 7. Install hub/bearing assembly dust cap, using a soft faced hammer. 8. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Rear Caliper Guide Pin Bolts 9. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer to Disc Brake Caliper Service and Repair for installation procedure. 10. Install rear wheel and tire assembly on vehicle, tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6996 11. Lower vehicle. Seal Grommet Installation In Floor Pan 12. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. Park Brake Cable Installed In Retaining Bracket 13. Route park brake cable under carpeting and up to park brake cable retaining bracket on floor pan. Then install park brake cable into retaining bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in retaining bracket. Park Brake Cables At Equalizer 14. Install rear park brake cables into equalizer on park brake lever cable. 15. Reposition rear carpeting. 16. Install both rear door sill plate scuff moldings, by snapping them onto rear door sills. 17. Install lower rear seat cushion. Be sure lower seat cushion is fully installed in retainers on floor pan of vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 6997 Removing Lockout Pin From Park Brake Lever 18. Firmly grasp park brake lever locking pin (3/16 in. drill bit) and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. 19. Cycle park brake lever ounce to position park brake cables. Then return the park brake lever to its released position. Check the rear wheels of the vehicle, they should rotate freely without dragging. 20. Apply park brake to full engagement. 21. Install center console assembly. 22. Install the center console assembly attaching screws. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper from rotor as described under Brake Pad/Service and Repair. 4. Remove rotor from hub. 5. Remove grease cap, cotter pin, locknut, retaining nut, washer, hub and bearings. 6. Using a suitable tool, remove forward hold-down clip. 7. Turn adjuster wheel until adjuster is at its shortest length, then remove adjuster assembly. 8. Remove upper shoe to shoe spring. 9. Pull front shoe away from anchor, then remove front shoe and lower spring. 10. Using a suitable tool, remove rear hold-down clip and shoe. 11. Reverse procedure to install noting the following: a. Adjust shoe diameter to 6.75 inches. b. Tighten wheel bearing adjusting nut to specifications while rotating hub to seat bearings, back off adjusting nut 1/4 turn, then tighten finger tight. c. Align nut-to-spindle holes for cotter pin insertion. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation DESCRIPTION Fig 1 Bendix Single Diaphragm Power Brake Unit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Description and Operation > Page 7005 Fig 2 Bendix Tandem Diaphragm Power Brake These units are of the vacuum suspended type. Some units are of the single diaphragm type, while others are of the tandem diaphragm type. Both single piston and double piston or split system type master cylinders are used. The vacuum suspended diaphragm type units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Description and Operation > Page 7006 elements combined into a single power unit. The three basic elements of the single diaphragm type are: 1. A vacuum power section which includes a front and rear shell, a power diaphragm, a return spring and a pushrod. 2. A control valve, integral with the power diaphragm and connected through a valve rod to the brake pedal, controls the degree of brake application or release in accordance with the pressure applied to the brake pedal. 3. A hydraulic master cylinder, attached to the vacuum power section which contains all the elements of the conventional brake master cylinder (except for the pushrod), supplies fluid under pressure to the wheel brakes in proportion to the pressure applied to the brake pedal. OPERATION Upon application of the brakes, the valve rod and plunger move to the left in the power diaphragm to close the vacuum port and open the atmospheric port to admit air through the air cleaner and valve at the rear diaphragm chamber. With vacuum present in the rear chamber, a force is developed to move the power diaphragm, hydraulic pushrod and hydraulic piston or pistons to close the compensating port or ports and force fluid under pressure through the residual check valve or valves and lines into the front and rear wheel cylinders to actuate the brakes. As pressure is developed within the master cylinder a counter force acting through the hydraulic pushrod and reaction disc against the vacuum power diaphragm and valve plunger sets up a reaction force opposing the force applied to the valve rod and plunger. This reaction force tends to close the atmospheric port and reopen the vacuum port. Since this force is in opposition to the force applied to the brake pedal by the driver it gives the driver a "feel" of the amount of brake applied. The proportion of reactive force applied to the valve plunger through the reaction disc is designed into the Master-Vac to ensure maximum power consistent with maintaining pedal feel. The reaction force is in direct proportion to the hydraulic pressure developed within the brake system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Vacuum Brake Booster: Symptom Related Diagnostic Procedures Decreasing Brake Pedal Travel If a decreasing brake pedal is encountered, the power brake unit may be binding internally. To test the power brake unit for this condition proceed as follows: 1. Place transmission shift lever in Neutral and START engine. 2. Increase engine speed to approximately 1500 rpm, close throttle and completely depress brake pedal. 3. Slowly release brake pedal and stop engine. 4. Remove vacuum check valve and hose from power brake unit. Observe brake pedal for backward movement. 5. If brake pedal moves backward, power brake unit has internal binding, and must be replaced. Dragging Brakes If brakes release slowly or incompletely (brakes drag), the power brake unit may be binding internally. To test for an internal bind condition, refer to Decreasing Brake Pedal Travel. Hard Brake Pedal A "hard" brake pedal could be caused by internal binding in the power unit or a failed vacuum check valve. Refer to Decreasing Brake Pedal Travel to test power brake unit for an internal bind. To check for a failed vacuum check valve, proceed as follows: 1. Start engine and increase engine speed to approximately 1500 rpm, then close throttle and stop engine. 2. Wait 90 seconds, then try brake action. 3. If brakes are not vacuum assisted for two or more applications, replace check valve. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7009 Vacuum Brake Booster: Component Tests and General Diagnostics General Service In order to properly service and repair available brake systems, a thorough understanding of the power assist systems is necessary. The vacuum assist diaphragm assembly multiplies the force exerted on the master cylinder piston in order to increase the hydraulic pressure delivered to the wheel cylinders or calipers while decreasing the effort necessary to obtain acceptable stopping performance. Vacuum assist units get their energy by opposing engine vacuum to atmospheric pressure. A piston, cylinder and flexible diaphragm utilize this energy to provide brake assistance. The diaphragm is balanced with engine vacuum until the brake pedal is depressed, allowing atmospheric pressure to unbalance the unit and apply force to the brake system. Brakes will operate even if the power unit fails. This means the conventional brake system and the power assist system are completely separate. Troubleshooting conventional and power assist systems are exactly the same until the power unit is reached. As with conventional hydraulic brakes, a spongy pedal still means air is trapped in the hydraulic system. Power brakes give higher line pressure, making leaks more critical. Checking Complaints Complaints about power brake operation should be handled as if two separate systems exist. Check for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick check of proper power unit operation, press the brake pedal firmly, then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position. Another check begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine off and the power unit not operating. Maintaining the same pedal height, start the engine and take another reading. There should be a substantial pressure increase in the second reading. Pedal free travel and total travel are critical on cars equipped with power brakes. Pedal travel should be kept strictly to specifications. Take a manifold vacuum reading if the power unit isn't giving enough assistance. Remember, though, currently produced emission controlled engines, manifold vacuum readings may be less than 15 inches Hg at idle. If manifold vacuum is abnormally low, tune the engine and then try the power brakes again. Naturally, loose vacuum lines and clogged air intake filters will cut down brake efficiency. Most units have a check valve that retains some vacuum in the system when the engine is off. A vacuum gauge check of this valve will tell you when it is restricted or stuck open or closed. Failure of the brakes to release in most instances is caused by a tight or misaligned connection between the power unit and the brake linkage. If this connection is free, inspect for a broken piston, diaphragm or bellows and return spring. A simple check of the hydraulic system should be made before proceeding. Loosen the connection between the master cylinder and the brake booster. If the brakes release, the trouble is in the power unit; if the brakes still will not release, look for a restricted brake line or similar difficulties in the hydraulic circuit. A residual pressure check valve is usually included immediately under the brake line connection on hydraulic assist power brakes. This valve maintains a slight hydraulic pressure within the brake lines and wheel cylinders or caliper to give better pedal response. If it is sticking, the brakes may not release. Power brakes that have a hard pedal are usually suffering from a milder form of the same ills that cause complete power unit failure. Collapsed or leaking vacuum lines or insufficient manifold vacuum, as well as punctured diaphragms or bellows and leaky piston seals, all lead to weak power unit operation. A steady hiss when the brake is held down means a vacuum leak that will cause poor power unit operation. Do not immediately condemn the power unit if the brakes grab. First look for all the usual causes, such as greasy linings, scored rotors or drums. Then investigate the power unit. When the trouble has been traced to the power unit, check for a damaged reaction control. The reaction control is usually made up of a diaphragm, spring and valves that tends to resist pedal action. It is put in the system to give the pedal "feel." Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7010 Vacuum Brake Booster: Adjustments PUSHROD ADJUSTMENT In some cases adjustment of the brake booster pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will cause the master cylinder piston to close off the compensating port, preventing hydraulic pressure from being released and resulting in brake drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the booster, master cylinder or pushrod are serviced, the pushrod may require adjustment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7011 Vacuum Brake Booster: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. When repairing vehicles equipped with Antilock Brake Systems (ABS), the vacuum in the power booster must be pumped down before removing the master cylinder to avoid drawing in any contamination. This can be done simply by pumping the brake until a firm pedal is achieved, with ignition off. 1. On models with ABS systems, ensure ignition switch is Off and brake pedal has been pumped until firm. 2. On all models, disconnect wiring harness from brake fluid level sensor mounted on fluid reservoir. 3. Disconnect primary and secondary brake tubes from master cylinder housing and plug outlets on master cylinder. 4. On models with ABS systems, clean area where master cylinder attaches to power booster using a suitable cleaner. 5. On all models, remove mounting nuts and slide master cylinder forward out of booster. 6. On models equipped with ABS, the vacuum seal in the front of the power brake vacuum booster must be replaced. Remove vacuum seal in front of power brake vacuum booster by carefully inserting a small screwdriver between the master cylinder push rod and vacuum seal and prying the seal out of the booster. Do not attempt to pry seal out by inserting screwdriver between seal and booster. 7. On all models, disconnect vacuum hoses from power booster check valve. Do not remove check valve from power booster. 8. On models with ABS systems, remove Hydraulic Control Unit (HCU). 9. On all models, locate power booster input rod to brake pedal attachment under instrument panel. Position a suitable small screwdriver between center tang on input rod to brake pedal pin retaining clip. Rotate screwdriver to allow retaining clip center tang to pass over end of brake pedal pin. Discard retaining clip. 10. Remove power booster mounting nuts holding unit to dash panel. 11. Slide power booster forward until mounting studs clear dash, then tilt unit upward to remove. 12. Reverse procedure to install noting the following: a. On models with ABS, install new vacuum seal by lubricating master cylinder push rod using Mopar Silicone Dielectric Compound - NO Substitutes. Slide vacuum seal onto master cylinder push rod with notches on seal pointing toward and seated against master cylinder housing. b. On all models, install mounting nuts and torque to 21 ft. lbs. c. Connect brake tubes to master cylinder primary and secondary ports and torque tube nuts to 12 ft. lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The relay box is mounted on the Hydraulic Control Unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7016 ABS Main Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7017 ABS Main Relay: Description and Operation ABS SYSTEM RELAY The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the control module. Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the left headlamp ground. When the system is operating normally, power for the contact side of the relay is supplied from the control module on the B47 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F18 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Relay Box Relay Box Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: Customer Interest ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON ABS Control Module: All Technical Service Bulletins ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 7034 ABS Control Module: Locations ABS Controller The controller is located in the passenger compartment, on the left kick panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 7035 Controller Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 7036 ABS Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 7037 ABS Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7043 39 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7044 43 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7045 45 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7046 47 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7047 51 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7048 55 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7049 57 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7050 59 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7051 63 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7052 67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7053 69 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7054 71 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7055 173 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7056 177 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7057 179 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7058 181 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7059 187 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7060 191 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7061 193 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7062 195 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7063 201 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7064 205 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7065 207 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7066 209 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 7067 256 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel Speed Sensors 1800 - 2600 ohms Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 7070 Wheel Speed Sensor: Mechanical Specifications Wheel Speed Sensor/Tone Wheel Air Gap 0.04 - 1.67 mm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Wheel Speed Sensor: Locations Front Wheel Speed Sensors Wheel Speed Sensor The front wheel speed sensors are located on the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 7073 Wheel Speed Sensor: Locations Rear Wheel Speed Sensors Wheel Speed Sensor The rear wheel speed sensors are located on the rear brake support plate. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 7076 Wheel Speed Sensor: Diagrams Rear Wheel Speed Sensor Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 7077 Wheel Speed Sensor: Description and Operation One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 7078 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 7084 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 7087 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 7097 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 7098 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 7099 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation Neutral Safety Switch: Description and Operation NAME OF CODE: Park/neutral Switch Failure WHEN MONITORED: with the transmission in park, neutral, or drive, and the transmission not in limp-in mode. SET CONDITION: If the transmision is in park or neutral, the engine must be cranking. If the transmission is in drive, the vehicle speed must be above 50 mph, the engine speed must be between 1,985 and 4,480 rpm, the TP sensor must not be closed, and the MAP must be above 66% of barometric pressure. THEORY OF OPERATION: The park/neutral position switch is used to communicate the state of the transmission to the idle air control (IAC) motor via the PCM. The IAC motor needs this information in order to determine the target idle speed. The IAC motor holds the idle speed at 600 rpm in park or neutral, while it increases the engine speed to about 800 rpm when the transmission is shifted into drive. Spark also is advanced in park or neutral position, while it is retarded in drive position. POSSIBLE CAUSES: - Dirty or melted connector contacts - Disconnected wiring harness - Park/neutral position switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Customer Interest for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Customer Interest for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 7116 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Customer Interest for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 7117 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set Technical Service Bulletin # 180697A Date: 970307 PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set NO: 18-06-97 Rev. A GROUP: Vehicle Performance DATE: Mar. 7, 1997 SUBJECT: Engine Slow Crank/MIL Illuminated - IAC DTC Hex **$19** Set THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-97, DATED FEB. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CORRECTION OF THE "HEX CODE". MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Engine will slowly crank and then start, immediately after starting the malfunction indicator light (MIL) will illuminate. When checked the "Idle Air Control(IAC)" will be set. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than any IAC related codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC for "Idle Air Control" Hex **$19** is found clear the code and perform the Repair Procedure. NOTE: VEHICLES BUILT PRIOR TO AUGUST 1, 1994 (MDH 08-01-XX) MUST HAVE THE POWERTRAIN CONTROL MODULE (PCM) REPLACED BEFORE PROCEEDING WITH THIS REPAIR. PARTS REQUIRED: AR 04874154 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- M/T) AR 04874155 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL-M/T) AR 04874156 Powertrain Control Module (2.0L MPI-FED-LOW ALT.- 3ATX) AR 04874157 Powertrain Control Module (2.0L MPI-FED & CAL- M/T)(ACR) AR 04874158 Powertrain Control Module (2.0L MPI-FED-HIGH ALT. & CAL -3ATX) 1 04796440 Cable, Positive Battery Kit EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Gable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1125 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-95 0.5 Hrs. Module, Powertrain Control - Reprogram 08-19-47-96 0.8 Hrs. Module, Powertrain Control - Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 7123 And Reprogram FAILURE CODE: FM - Flash Module Repair Procedure This repair involves cleaning or replacing the positive battery cable, replacing the PCM on early built vehicles and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). Positive Battery Cable Replacement 1. Record preset radio settings. 2. With the ignition key in the OFF position, disconnect the negative battery terminal. 3. Disconnect the positive battery terminal and remove and discard the entire cable assembly. 4. Install the new positive battery cable double eyelet to the power distribution center (PDC). Torque each nut to 35 in.lb. (4 Nm). 5. Install the bolt/stud to the starter cable eyelet with the flats of the starter cable aligned with the flats on the bolt. Torque to 105 in.lbs. (12 Nm). 6. Clean both battery posts and inside of negative terminal. 7. Install the positive battery terminal and then the negative. CAUTION: INSURE THAT THE TERMINALS ARE INSTALLED NO HIGHER THAN FLUSH WITH THE POSTS. THIS WILL INSURE THAT THE THERMOGUARD WILL SNAP TOGETHER PROPERLY. 8. Torque each terminal to 7.4 Nm (65 in.lbs.) and coat the top of the positive terminal with grease. NOTE: TURN THE IGNITION KEY TO THE ON POSITION AND DO NOT START THE ENGINE FOR TWO TO THREE SECONDS. THIS WILL ALLOW THE IAC TO POSITION ITSELF AND PREVENT STALLING. 9. Verify proper charging system operation before proceeding. 10. Reset radio preset recorded in step 1. Powertrain Control Module Flash Procedure 1. If the vehicle was built prior to August 1,1994 (MDH 08-01-XX) replace the PCM before proceeding. 2. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable: > 180697A > Mar > 97 > PCM/Battery Cable - Slow Start/MIL ON/DTC #19 Set > Page 7124 10. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. 12. Start and run the vehicle, then check for DTC's and repair as needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 7128 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation BATTERY TEMPERATURE SENSOR From circuit G31, the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 49 of the PCM connector, and cavity B of the sensor connector. The PCM provides a ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector and cavity A of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor Operation > Page 7131 Battery Temperature Sensor: Description and Operation Battery Temp Sensor Voltage Out of Limit NAME OF CODE: Battery Temp. Sensor Volts Out of Limit WHEN MONITORED: With the ignition key ON. SET CONDITION: There is a circuit problem in the sensor circuit internal to the Powertrain Control Module (PCM). THEORY OF OPERATION: The battery temp sensor voltage is used to determine what goal voltage to use for the charging system based on ambient temperature near the battery. POSSIBLE CAUSES: - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Throttle position sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Service and Repair Generator: Service and Repair 1. Disconnect battery ground cable. 2. Loosen alternator adjustment nut. 3. Turn front wheels fully to right, then raise and support vehicle. 4. Remove lower splash shield. 5. Disconnect alternator wiring. 6. Loosen alternator pivot bolt. 7. Remove alternator drive belt. 8. Remove three bolts from pivot bracket. 9. Remove pivot nut from T-bolt while supporting alternator. 10. Lower alternator and remove through wheelwell. 11. Reverse procedure to install, noting the following: a. Torque alternator mounting bolts to 40 ft.-lbs. b. Torque alternator feed terminal nut to 75 in.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 083095 > Aug > 95 > Air Bag - Lamp Intermittantly ON /Inoperative Components Ignition Lock: Customer Interest Air Bag - Lamp Intermittantly ON /Inoperative Components NO: 08-30-95 GROUP: Electrical DATE: Aug. 4, 1995 SUBJECT: Intermittent Air Bag Light Illumination, and Inoperative Electrical Components Following Engine Start-up MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Intermittently the air bag light remains illuminated, and the power windows, radio, turn signals, wipers, and climate control are inoperative following engine start-up. NOTE: THIS FAILURE MODE HAS NO EFFECT ON THE ABILITY OF THE AIRBAG SYSTEM DIAGNOSTIC MODULE TO DEPLOY THE AIRBAGS IN CASE OF AN ACCIDENT. DIAGNOSIS: Start the vehicle and allow the ignition switch to normally return from the start position to the run position, without forcing it. If any of the conditions are present, as indicated above, carefully rotate the ignition switch back towards the run position. If the electrical components are now functional, proceed to the following diagnostic steps. ^ Remove the steering column cover liner, the lower steering column shroud and the key lock cylinder as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 19-37. ^ Install the key lock cylinder without the lower steering column shroud in place. ^ Start the vehicle and allow the switch to normally return from the start position to the run position, without forcing it. If the key lock cylinder normally returns to the run position and all electrical components are now functional, proceed to the repair procedure. If the electrical components are still not functioning, further diagnosis and repairs will be necessary and will not be covered in this bulletin. REPAIR PROCEDURE: This bulletin involves removing material from the lower steering column shroud around the key lock cylinder opening. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 083095 > Aug > 95 > Air Bag - Lamp Intermittantly ON /Inoperative Components > Page 7150 1. With the lower steering column shroud off the vehicle, remove approximately .040" (1 mm) of material from the upper inside diameter of the key lock cylinder opening. Use a rattail file, utility knife or tapered reamer to remove the necessary material. See Illustration. 2. Install the lower column shroud on the column and secure in place with the three screws. Install the key lock cylinder in place. 3. Verify that the switch returns to the run position after starting and all electrical components are functioning properly. If not, additional material will have to be removed from the lower column shroud. 4. Install the steering column cover liner back on the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-36-91 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 083095 > Aug > 95 > Air Bag - Lamp Intermittantly ON /Inoperative Components Ignition Lock: All Technical Service Bulletins Air Bag - Lamp Intermittantly ON /Inoperative Components NO: 08-30-95 GROUP: Electrical DATE: Aug. 4, 1995 SUBJECT: Intermittent Air Bag Light Illumination, and Inoperative Electrical Components Following Engine Start-up MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Intermittently the air bag light remains illuminated, and the power windows, radio, turn signals, wipers, and climate control are inoperative following engine start-up. NOTE: THIS FAILURE MODE HAS NO EFFECT ON THE ABILITY OF THE AIRBAG SYSTEM DIAGNOSTIC MODULE TO DEPLOY THE AIRBAGS IN CASE OF AN ACCIDENT. DIAGNOSIS: Start the vehicle and allow the ignition switch to normally return from the start position to the run position, without forcing it. If any of the conditions are present, as indicated above, carefully rotate the ignition switch back towards the run position. If the electrical components are now functional, proceed to the following diagnostic steps. ^ Remove the steering column cover liner, the lower steering column shroud and the key lock cylinder as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 19-37. ^ Install the key lock cylinder without the lower steering column shroud in place. ^ Start the vehicle and allow the switch to normally return from the start position to the run position, without forcing it. If the key lock cylinder normally returns to the run position and all electrical components are now functional, proceed to the repair procedure. If the electrical components are still not functioning, further diagnosis and repairs will be necessary and will not be covered in this bulletin. REPAIR PROCEDURE: This bulletin involves removing material from the lower steering column shroud around the key lock cylinder opening. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 083095 > Aug > 95 > Air Bag - Lamp Intermittantly ON /Inoperative Components > Page 7156 1. With the lower steering column shroud off the vehicle, remove approximately .040" (1 mm) of material from the upper inside diameter of the key lock cylinder opening. Use a rattail file, utility knife or tapered reamer to remove the necessary material. See Illustration. 2. Install the lower column shroud on the column and secure in place with the three screws. Install the key lock cylinder in place. 3. Verify that the switch returns to the run position after starting and all electrical components are functioning properly. If not, additional material will have to be removed from the lower column shroud. 4. Install the steering column cover liner back on the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-36-91 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Page 7157 Ignition Lock: Service and Repair Ignition Switch Replacement Fig. 6 Ignition Lock Cylinder Detentes LOCK KEY CYLINDER The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Fig. 2 Steering Column Shrouds REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Page 7158 Fig. 7 Socket In Lock Cylinder Housing INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description Ignition Switch: Description and Operation Ignition Switch Description IGNITION SWITCH When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22 through the ignition switch. A 30 amp maxi fuse in the PDC protects circuits A2 and A22. ^ Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits F20, C1, L5 and F25. Circuit F20 splices to power the back-up lamp switch, heated rear window switch, and A/C compressor cycling switch. ^ Circuit C1 feeds the HVAC blower motor. A 25 amp fuse in the fuse block, cavity 7, protects circuit C1. ^ Circuit L5 powers the turn signals. A 10 amp fuse in the fuse block, cavity 6, protects circuit L5. ^ Circuit F25 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 5, protects circuit F25. Also in the RUN position, the ignition switch connects circuit A1 from the PDC to circuit A21. A 30 amp maxi fuse in the PDC protects circuits A1 and A21. Circuit A21 feeds a bus bar in the fuse block. The bus bar feeds circuits G5, F18, and F15. ^ Circuit G5 powers the gauge cluster warning lamps and the Daytime Running Lamp (DRL) module. Fuse cavity 11 (5 amp) in the fuse block protects circuit G5. ^ Circuit F18 splices to the Powertrain Control Module (PCM), duty cycle purge solenoid, EGR solenoid, ABS system, and a bus bar in the PDC. The bus bar in the PDC feeds the coil side of the radiator fan relay, A/C compressor clutch relay, and the fuel pump relay. A 15 amp fuse in the fuse block, cavity 10, protects circuit F18. ^ Circuit F15 feeds the airbag control module. A 10 amp fuse in the fuse block, cavity 9, protects circuit F15. In the RUN or ACCESSORY position, the ignition switch connects circuits A1 and A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds circuits X12 and F13. A 30 amp maxi fuse in the PDC protects circuits A1 and A31. ^ Circuit X12 powers the radio. A 10 amp fuse in the fuse block, cavity 16, protects circuit X12. ^ Circuit F13 powers the windshield wiper system. A 20 amp fuse in the fuse block, cavity 15, protects circuit F13. In the START position, the ignition switch connects circuits A1 and A41. Circuit A41 powers the coil side of the starter relay. On manual transaxle vehicles, the clutch position switch opens and closes circuit A41. The clutch position switch closes when the operator depresses the clutch pedal. On automatic transaxle vehicles, a jumper is used in the harness instead of the switch. In the START position, the ignition switch connects circuit G9 to circuit Z1. This provides a ground path to illuminate the brake warning lamp. Circuit G9 splices to the brake warning switch and park brake switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Ignition Switch Description > Page 7163 Ignition Switch: Description and Operation Time Delay Relay/Ignition Switch Lamp TIME DELAY RELAY/IGNITION SWITCH LAMP The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is received on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). When a door is opened, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, closing the contacts. When the relay contacts are closed, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 7164 Ignition Switch: Service and Repair Fig. 1 Ignition Switch -- Viewed From Below Column Fig. 2 Steering Column Shrouds NOTE: The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in Run position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower column shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig. 3 Ignition Switch Mounting Screw 5. Remove ignition switch mounting screw with a #10 Torx® bit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 7165 Fig. 4 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. Fig. 5 Ignition Switch Installation INSTALLATION 1. Ensure the ignition switch is in the Run position and the actuator shaft in the lock housing is in the Run position. 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the Run position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation Neutral Safety Switch: Description and Operation NAME OF CODE: Park/neutral Switch Failure WHEN MONITORED: with the transmission in park, neutral, or drive, and the transmission not in limp-in mode. SET CONDITION: If the transmision is in park or neutral, the engine must be cranking. If the transmission is in drive, the vehicle speed must be above 50 mph, the engine speed must be between 1,985 and 4,480 rpm, the TP sensor must not be closed, and the MAP must be above 66% of barometric pressure. THEORY OF OPERATION: The park/neutral position switch is used to communicate the state of the transmission to the idle air control (IAC) motor via the PCM. The IAC motor needs this information in order to determine the target idle speed. The IAC motor holds the idle speed at 600 rpm in park or neutral, while it increases the engine speed to about 800 rpm when the transmission is shifted into drive. Spark also is advanced in park or neutral position, while it is retarded in drive position. POSSIBLE CAUSES: - Dirty or melted connector contacts - Disconnected wiring harness - Park/neutral position switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 083996 > Nov > 96 > Vehicle - No Crank/No Start/Solenoid Clicks Starter Motor: Customer Interest Vehicle - No Crank/No Start/Solenoid Clicks NO: 08-39-96 GROUP: Electrical DATE: Nov. 15, 1996 SUBJECT: Vehicle Will Not Start - Starter Solenoid Clicks With No Motor Engagement MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Vehicle will not start, starter solenoid clicks with no motor engagement. This mainly occurs after high humidity and cold ambient temperatures of 32 degrees and below. The no start condition is caused by internal icing in the starter solenoid. Corrosion from earlier freezing can also produce the same symptom in warmer weather. DIAGNOSIS: If vehicle is in freezing temperatures, listen for starter solenoid clicking, if motor does not engage, proceed to the Repair Procedure. If vehicle is located in temperatures above freezing, inspect the starter for signs of corrosion or moisture, if found proceed to the Repair Procedure. PARTS REQUIRED: 1 04793210 Starter Assembly REPAIR PROCEDURE: This bulletin involves the replacement of the starter with a new sealed starter. 1. Disconnect battery negative cable. 2. Raise vehicle. 3. On vehicles equipped with A/C: ^ Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. ^ Remove the front engine mount bolt from the insulator and front crossmember mounting bracket. ^ Lower the front of the engine, rotate the engine forward allowing easier removal of the starter motor. 4. For easier servicing, do not remove the wiring from the starter at this time. 5. Remove the two bolts attaching the starter to the transmission housing. 6. Remove the starter/starter solenoid assembly from the transmission housing. Position the starter to gain access to the wiring connectors. 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect the push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move aside the A/C plumbing as necessary. 11. Install the new starter, by inserting through the same path as old starter was removed from. 12. Clean the corrosion1dirt from the cable and wire terminals before installing the wiring to the solenoid. 13. Connect the battery positive and generator out-put wire to the starter solenoid post. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 083996 > Nov > 96 > Vehicle - No Crank/No Start/Solenoid Clicks > Page 7177 CAUTION: IT IS CRITICAL THAT THE GENERATOR OUTPUT TERMINAL BE CONNECTED TO THE BATTERY POSITIVE TERMINAL OF THE STARTER SOLENOID, FOR PROPER OPERATION OF THE CHARGING AND CRANKING SYSTEMS. 14. Connect the push-on solenoid connector. 15. Position the starter face into the transmission housing. Support the starter in pilot and start the top bolt. 16. Attach the ground cable to the lower mounting bolt and start bolt. 17. Ensure the proper starter alignment before torquing the starter mounting bolts to 54 Nm (40 ft. lbs.). 18. Vehicles equipped with A/C: ^ Using a floor jack or jack stand, raise the engine and transmission assembly to the original position. ^ Install the front engine mount bolt through the insulator and front crossmember mounting bracket. ^ Torque the bolt to 54 Nm (40 ft. lbs.) 19. Lower vehicle and connect battery cables. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-75-01-91 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 083996 > Nov > 96 > Vehicle - No Crank/No Start/Solenoid Clicks Starter Motor: All Technical Service Bulletins Vehicle - No Crank/No Start/Solenoid Clicks NO: 08-39-96 GROUP: Electrical DATE: Nov. 15, 1996 SUBJECT: Vehicle Will Not Start - Starter Solenoid Clicks With No Motor Engagement MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Vehicle will not start, starter solenoid clicks with no motor engagement. This mainly occurs after high humidity and cold ambient temperatures of 32 degrees and below. The no start condition is caused by internal icing in the starter solenoid. Corrosion from earlier freezing can also produce the same symptom in warmer weather. DIAGNOSIS: If vehicle is in freezing temperatures, listen for starter solenoid clicking, if motor does not engage, proceed to the Repair Procedure. If vehicle is located in temperatures above freezing, inspect the starter for signs of corrosion or moisture, if found proceed to the Repair Procedure. PARTS REQUIRED: 1 04793210 Starter Assembly REPAIR PROCEDURE: This bulletin involves the replacement of the starter with a new sealed starter. 1. Disconnect battery negative cable. 2. Raise vehicle. 3. On vehicles equipped with A/C: ^ Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. ^ Remove the front engine mount bolt from the insulator and front crossmember mounting bracket. ^ Lower the front of the engine, rotate the engine forward allowing easier removal of the starter motor. 4. For easier servicing, do not remove the wiring from the starter at this time. 5. Remove the two bolts attaching the starter to the transmission housing. 6. Remove the starter/starter solenoid assembly from the transmission housing. Position the starter to gain access to the wiring connectors. 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect the push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move aside the A/C plumbing as necessary. 11. Install the new starter, by inserting through the same path as old starter was removed from. 12. Clean the corrosion1dirt from the cable and wire terminals before installing the wiring to the solenoid. 13. Connect the battery positive and generator out-put wire to the starter solenoid post. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 083996 > Nov > 96 > Vehicle - No Crank/No Start/Solenoid Clicks > Page 7183 CAUTION: IT IS CRITICAL THAT THE GENERATOR OUTPUT TERMINAL BE CONNECTED TO THE BATTERY POSITIVE TERMINAL OF THE STARTER SOLENOID, FOR PROPER OPERATION OF THE CHARGING AND CRANKING SYSTEMS. 14. Connect the push-on solenoid connector. 15. Position the starter face into the transmission housing. Support the starter in pilot and start the top bolt. 16. Attach the ground cable to the lower mounting bolt and start bolt. 17. Ensure the proper starter alignment before torquing the starter mounting bolts to 54 Nm (40 ft. lbs.). 18. Vehicles equipped with A/C: ^ Using a floor jack or jack stand, raise the engine and transmission assembly to the original position. ^ Install the front engine mount bolt through the insulator and front crossmember mounting bracket. ^ Torque the bolt to 54 Nm (40 ft. lbs.) 19. Lower vehicle and connect battery cables. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-75-01-91 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 7184 Starter Motor: Specifications Free Speed Test Power Rating, Kw ................................................................................................................................ ....................................................................... 0.95 Max. Amps ........................................................... ........................................................................................................................................................... -- Volts ................................................................................................................................................. ............................................................................... -Minimum RPM ..................................................................................................................................... ............................................................................... -- Cranking Amp Draw Test [01] .......................... ....................................................................................................................................................... 150-180 [01] -- With engine @ operating temperature. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 7185 Starter Motor: Description and Operation STARTING SYSTEM COMPONENTS The starting system has: Ignition switch - Starter relay - Neutral starting and back up switch - Wiring harness - Battery - Starter motor with an integral solenoid BOSCH STARTER OPERATION The Bosch is a permanent magnet starter motor. A planetary gear train transmits power between starter motor and pinion shaft. - The fields have six permanent magnets. SUPPLY CIRCUIT AND CONTROL CIRCUIT The starter system consists of two separate circuits: A high amperage supply to feed the starter motor. - A low amperage circuit to control the starter solenoid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C Starter Motor: Service and Repair With A/C Fig. 6 Remove And Install Battery Cables STARTER REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. 3. Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. Fig. 12 Front Engine Mount Bolt Removal 4. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket. 5. Lower engine to rotate it forward to allow easy removal of starter motor. 6. For easier servicing, do not remove the wiring from starter at this time. Fig. 13 Starter Removal Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 7188 7. Remove two bolts attaching starter to transmission housing. 8. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors. Fig. 14 Wire Connection 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move a side A/C plumbing as necessary. INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Connect the battery positive and generator output wire to the starter solenoid post. CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Connect the push-on solenoid connector. 4. Set starter face into transmission housing. Support starter in pilot and start the top bolt. 5. Attach ground cable to lower mounting bolt and start bolt. 6. Tighten both mounting bolts to 30 Nm (40 ft lb) torque and assuring proper starter alignment. 7. Using a floor jack or jack stand, raise the engine and transmission assembly to the original position. 8. Install the front engine mount through bolt through the insulator and front crossmember mounting bracket. 9. Tighten bolt to 54 Nm (40 ft lb) torque. 10. Lower vehicle and connect battery cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 7189 Starter Motor: Service and Repair Without A/C Fig. 6 Remove And Install Battery Cables STARTER REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. 3. For easier servicing, do not remove the wiring from starter at this time. Fig. 13 Starter Removal 4. Remove two bolts attaching starter to transmission housing. 5. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors. Fig. 14 Wire Connection Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 7190 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move a side A/C plumbing as necessary. INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Connect the battery positive and generator output wire to the starter solenoid post. CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Connect the push-on solenoid connector. 4. Set starter face into transmission housing. Support starter in pilot and start the top bolt. 5. Attach ground cable to lower mounting bolt and start bolt. 6. Tighten both mounting bolts to 30 Nm (40 ft lb) torque and assuring proper starter alignment. 7. Lower vehicle and connect battery cables. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 7198 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 7199 Power Distribution Center: Description and Operation Fig. 1 Power Distribution Center (PDC) The Power Distribution Center (PDC) is located next to the battery. The PDC contains: Starter Relay - Radiator Fan Relay - A/C Compressor Clutch Relay - Auto Shutdown (ASD) Relay - Fuel Pump Relay - and several fuses Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 Fuse: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 Fuse: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Fuse: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 Fuse Block: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 Fuse Block: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 Fuse Block: Mechanical Diagrams Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 7275 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 7276 Power Distribution Center: Description and Operation Fig. 1 Power Distribution Center (PDC) The Power Distribution Center (PDC) is located next to the battery. The PDC contains: Starter Relay - Radiator Fan Relay - A/C Compressor Clutch Relay - Auto Shutdown (ASD) Relay - Fuel Pump Relay - and several fuses Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Fuse: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Fuse: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 Fuse: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7305 Fuse Block: Connector Views Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7306 Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7307 Fuse Block: Electrical Diagrams Fuseblock (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7308 Fuseblock (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7309 Fuseblock (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7310 Fuseblock (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 Fuse Block: Mechanical Diagrams Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Panel Information Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Relay Box: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 Relay Box: Connector Views Power Distribution Center Front View Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 Front Of Fuse Block Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 Relay Box: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 Power Distribution Center (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 Power Distribution Center (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 Power Distribution Center (Part 4 Of 4) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 Relay Box: Mechanical Diagrams Fig.21 Power Distribution Center Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 Fig.20 Fuse Block Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7357 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7358 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7364 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7365 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 7370 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020694 > Jul > 94 > Alignment Specification - Revisions Alignment: All Technical Service Bulletins Alignment Specification - Revisions NO: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 SUBJECT: Service Manual Revision - Alignment Specifications MODELS: 1995 (PL) Neon DISCUSSION: This technical service bulletin references revised service manual pages. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 2-67 Alignment Specifications For Sales Code ACR POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Alignment Specifications For Sales Code ACR Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions > Page 7379 2-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 7385 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 020694 > Jul > 94 > Alignment Specification - Revisions Alignment: All Technical Service Bulletins Alignment Specification - Revisions NO: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 SUBJECT: Service Manual Revision - Alignment Specifications MODELS: 1995 (PL) Neon DISCUSSION: This technical service bulletin references revised service manual pages. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 2-67 Alignment Specifications For Sales Code ACR POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 02-06-94 GROUP: Suspension DATE: Jul. 1, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGES Alignment Specifications For Sales Code ACR Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-06-94 > Jul > 94 > Steering/Suspension - Alignment Specifications Revisions > Page 7394 2-67 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7395 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7396 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7397 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7398 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7399 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7400 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications Alignment: Specifications Front Alignment Specifications The content of this article reflects the changes called out by TSB 02-06-94. CAMBER [01] Limits Neon .................................................................................................................................................... ................................................... -0.4° to +0.4° ACR ........................................................................... ............................................................................................................................. -2.4° to +0.4° Desired ................................................................................................................................................ ........................................................................... 0° CASTER [01] Limits ................................................................................................................................................... ....................................................... +1.8° to +3.8° Desired ................................................................. ....................................................................................................................................................... 2.8° CROSS-CASTER [02] Limits ................................................................................................................................................... ............................................................ 1.0° or less Desired ................................................................ ........................................................................................................................................................ 0.0° TOTAL TOE Limits Neon .................................................................................................................................................... ................................................... -0.1° to +0.3° ACR ........................................................................... ............................................................................................................................. -0.7° to +0.3° Desired ................................................................................................................................................ ........................................................................ 0.1° [01] -- Reference angle only. Not adjustable. [02] -- Side to side caster differential not to exceed 1.0° or less. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications > Page 7403 Alignment: Specifications Rear Alignment Specifications The content of this article reflects the changes called out by TSB 02-06-94. CAMBER [01] Limits Neon .................................................................................................................................................... ............................................... -0.75° to +0.25° ACR ........................................................................... ........................................................................................................................... -1.0° to +0.25° Desired ................................................................................................................................................ ..................................................................... -0.25° TOTAL TOE [01] Limits Neon .................................................................................................................................................... ................................................... -0.1° to +0.3° ACR ........................................................................... ............................................................................................................................. -0.5° to +0.3° Desired ................................................................................................................................................ ...................................................................... +0.1° THRUST ANGLE [01] .......................................................................................................................... .......................................................... -0.1° to +0.1° [01] -- Reference angle only. Non-adjustable. NOTE: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is Toe-in, negative is Toe-out. Total toe must be equally splt between each front wheel to ensure a centered steering wheel. Left and Right toe must be equal to within 0.02°. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. NOTE: No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Center steering wheel and lock in place using steering wheel clamp. 3. Jounce vehicle, then read front alignment settings and compare to specifications. 4. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 5. Raise and support vehicle, then remove original upper bolt attaching front strut clevis bracket to steering knuckle. 6. Loosen lower bolt attaching strut clevis bracket to steering knuckle only enough to allow knuckle to move in clevis bracket. 7. Install bolt from service kit into upper strut clevis bracket to steering knuckle mounting hole. 8. Install nut provided by service kit on replacement bolt. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 7406 9. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 10. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 11. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 12. Adjust camber to preferred setting by pushing or pulling top of tire. 13. Tighten upper and lower strut clevis bracket bolts. 14. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque both front strut clevis brackets to 40 ft. lbs. plus an additional 1/4 turn. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams, until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 7407 Preliminary Inspection - Ensure vehicle has a full tank of gas when wheel alignment specifications are checked or adjusted. One full tank of gas is approximately 75 lbs. - If tank is not full, this change in weight will affect curb height of vehicle and alignment specifications. - Check and adjust tire pressure. Ensure all tires are the same size. - Inspect all suspension components for looseness or damage. Components showing signs of wear or damage should be replaced before alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 7408 Alignment: Service and Repair Rear Alignment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. - No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Jounce vehicle and read rear alignment settings and compare to specifications. 3. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 4. Raise and support vehicle, then remove original upper bolt attaching rear strut clevis bracket to rear knuckle. 5. Loosen lower bolt attaching strut clevis bracket to rear knuckle only enough to allow knuckle to move in clevis bracket. 6. Install bolt from service kit into upper strut clevis bracket to rear knuckle mounting hole. 7. Install nut provided by service kit on replacement bolt. 8. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 9. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 10. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 11. Adjust camber to preferred setting by pushing or pulling top of tire. 12. Tighten upper and lower strut clevis bracket bolts. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 7409 13. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque rear strut clevis brackets to 70 ft.-lbs. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 7420 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 7426 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 7431 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 7432 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 7433 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch Service Manual Revision > Page 7434 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7439 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7440 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7441 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7442 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7448 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7449 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7450 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7451 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7456 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7457 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7458 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7459 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 7462 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 7463 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 7485 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Ball Stud: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 7495 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 7496 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Ball Stud: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 7502 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 7503 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions Ball Stud: All Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7508 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7509 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7510 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7511 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7512 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions Ball Stud: All Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7518 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7519 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7520 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7521 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7522 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Page 7523 Ball Stud: Service and Repair 1. Remove cotter pin, castle nut and hub nut while vehicle is still on floor with brakes applied. 2. Raise and support vehicle, then remove front tire and wheel assembly. 3. Remove front disc brake caliper and place aside. CAUTION: Do not let caliper assembly hang by hose. 4. Remove front disc brake, then disconnect tie rod from steering knuckle using removal tool No. MB-990635, or equivalent. 5. Separate ball joint stud from steering knuckle by prying down on lower control arm. Ensure ball joint seal is not damage. 6. Pull steering knuckle assembly out and away from outer CV joint of driveshaft assembly. 7. Remove two steering knuckle to strut damper attaching bolts, then the steering knuckle and hub/bearing assembly from vehicle. 8. Reverse procedure to install. Torque clamp bolt to 70 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair 1. Ensure power steering fluid reservoir is full, then start and run engine. If fluid level drops after engine has been run, fill and run again until level remains constant. 2. Raise and support front of vehicle, then start engine and turn steering wheel slowly from stop to stop. 3. Stop engine and add fluid as necessary, then lower vehicle and restart engine. 4. Turn steering wheel slowly from stop to stop, then stop engine again and add fluid as necessary. 5. Inspect fluid condition. If it appears extremely foamy, do not disturb vehicle for several minutes, then repeat bleed procedure. Inspect for leaks. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 7536 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7542 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7543 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7544 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 7549 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7555 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7556 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7557 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps Power Steering Line/Hose: Customer Interest Power Steering System - Rattle Noise on Bumps NO: 19-06-94 GROUP: Steering DATE: Aug. 5, 1994 SUBJECT: Power Steering System Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 7/11/94, MDH (07-11-XX), EQUIPPED WITH POWER STEERING. SYMPTOM/CONDITION: A metallic rattle that appears to be coming from the front suspension or through the steering column. This noise usually occurs when the vehicle is driven through a turn and the tire goes over a pot hole, tar strip, or other surface irregularity. PARTS REQUIRED: 1 4626896 Power Steering Fluid Return Line 1 4361097 O-Ring, Banjo Bolt to Hose 1 4626691 O-Ring, Hose to Pump AR 4318085 Power Steering Fluid (16 Oz) AR 4549617 Power Steering Fluid (1 Qt) REPAIR PROCEDURE: This bulletin involves replacing the power steering fluid return line with a revised part and tightening the power steering pump housing bolts to a revised torque specification. 1. Remove the power steering fluid return line and install the revised power steering fluid return line, P/N 4626896, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-13 to 19-15. 2. Before adding power steering fluid to the proper level, proceed to Step 3. 3. Remove the power steering pump as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 19-16. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps > Page 7566 4. Tighten the four power steering pump housing bolts to 243 In.Lbs. (27 N-m). See Illustration. NOTE: IF THESE BOLTS ARE NOT TIGHTENED TO THE REVISED TORQUE SPECIFIED, PUMP NOISE ON COLD STARTS MAY BECOME UNACCEPTABLE. 5. Install the power steering pump in the vehicle and refill the system with fluid as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-17 to 19-18. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps Power Steering Line/Hose: All Technical Service Bulletins Power Steering System - Rattle Noise on Bumps NO: 19-06-94 GROUP: Steering DATE: Aug. 5, 1994 SUBJECT: Power Steering System Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 7/11/94, MDH (07-11-XX), EQUIPPED WITH POWER STEERING. SYMPTOM/CONDITION: A metallic rattle that appears to be coming from the front suspension or through the steering column. This noise usually occurs when the vehicle is driven through a turn and the tire goes over a pot hole, tar strip, or other surface irregularity. PARTS REQUIRED: 1 4626896 Power Steering Fluid Return Line 1 4361097 O-Ring, Banjo Bolt to Hose 1 4626691 O-Ring, Hose to Pump AR 4318085 Power Steering Fluid (16 Oz) AR 4549617 Power Steering Fluid (1 Qt) REPAIR PROCEDURE: This bulletin involves replacing the power steering fluid return line with a revised part and tightening the power steering pump housing bolts to a revised torque specification. 1. Remove the power steering fluid return line and install the revised power steering fluid return line, P/N 4626896, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-13 to 19-15. 2. Before adding power steering fluid to the proper level, proceed to Step 3. 3. Remove the power steering pump as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 19-16. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 190694 > Aug > 94 > Power Steering System - Rattle Noise on Bumps > Page 7572 4. Tighten the four power steering pump housing bolts to 243 In.Lbs. (27 N-m). See Illustration. NOTE: IF THESE BOLTS ARE NOT TIGHTENED TO THE REVISED TORQUE SPECIFIED, PUMP NOISE ON COLD STARTS MAY BECOME UNACCEPTABLE. 5. Install the power steering pump in the vehicle and refill the system with fluid as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 19-17 to 19-18. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 7581 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 7586 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7592 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7593 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7594 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 7599 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 7604 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7610 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7611 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 7612 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Measurements Given are in ft-lbs unless otherwise specified. Outer Tie Rod End Locknut ................................................................................................................. ..................................................................... 45 ft-lbs Power Steering Hose Tube Nuts ......................................................................................................... ...................................................................... 22 ft-lbs Power Steering Pump Relief Valve Ball Seat ........................................................................................................................................................... 48 in-lbs Pressure Hose Banjo Bolt ................................................................................................................... ...................................................................... 25 ft-lbs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7615 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Power Steering Pump Pressure, psi Test Valve Open [01].................................................................. ................................................................................................................................... 50-80 Test Valve Closed [02]................................................................................................................................. ......................................................... 1195-1293 Max Relief Pressure ................................................ .............................................................................................................................................. 1195-1293 Output Flow [03]................................................................................................................. ...................................................................................... 1.3-1.9 [01] -- Initial pressure. [02] -- Do not leave valve closed for more than five seconds. [03] -- At 1500 RPM & minimum pressure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7616 Power Steering Pump: Testing and Inspection Fig.4 Data Link Connector The diagnostic testing procedure provided in this section applies only to speed proportional steering systems. Diagnostic Trouble Code (DTC) 35 applies only to the speed proportional steering test.A DRB or equivalent scan tool is necessary to access the speed proportional power steering diagnostic trouble codes. Connect DRB scan tool or equivalent to data link connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7617 Fig.5 Speed Proportional Steering Test Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7618 Fig.6 Test Verification Procedure The diagnostic cycle begins when the ignition is turned to the On position. The condition required to set Diagnostic Trouble Code 35 is driving the vehicle in OD and achieving 1st through 4th electronically modulated converter clutch (EMCC). After completing diagnostic tests perform verification procedures, when required. Fig.7 Speed Proportional Power Steering Wiring Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7619 Fig.8 Transmission Control Module Wiring Diagram Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Removal and Installation Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation 1. Disconnect battery ground cable, then the power steering pressure hose from power steering pump. 2. Remove power steering fluid supply hose to power steering suction fitting, then the power steering fluid supply hose. 3. Remove two power steering pump to cast bracket mounting and adjusting bolts. 4. Loosen bolt attaching front power steering pump mounting bracket to front engine mount only far enough to slide bracket from behind bolt. 5. Remove drive belt, then the power steering pump and bracket as an assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Removal and Installation > Page 7622 Power Steering Pump: Service and Repair Power Steering Pump Serviceability The power steering pump is not serviceable except for the reservoirs and related components, filler cap/dipstick and any oil seals other than the pump shaft seal. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set Power Steering Pressure Switch: Customer Interest PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Customer Interest: > 181594 > Aug > 94 > PCM MIL ON/DTC 65 Set > Page 7632 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set Power Steering Pressure Switch: All Technical Service Bulletins PCM - MIL ON/DTC 65 Set NO: 18-15-94 GROUP: Vehicle Performance DATE: Aug. 12, 1994 SUBJECT: Check Engine Light On, Code 65, Power Steering Switch Failure MODELS: 1995 (PL) Neon NOTE: THIS SERVICE BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO May 26, 1994 (MDH 05-26-XX) AND NOT EQUIPPED WITH POWER STEERING SYMPTOM/CONDITION: The "Check Engine" light illuminates with Diagnostic Trouble Code "Power Steering Switch Failure" set (Flash Code # 65). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with appropriate diagnostic procedure manual, verify that all systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than "Power Steering Switch Failure" (Flash Code # 65) are present, record them on the repair order for future reference, and repair as necessary. If no other codes are present, the vehicle is not equipped with power steering, and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4796589 Wiring Assembly - Power Steering Switch Repair (Use with manual transmission equipped vehicles without heated rear window) 1 4793069 Wiring Assembly - Power Steering Switch Repair (All automatic transmission or those manual transmission equipped vehicles with heated rear window) REPAIR PROCEDURE: This bulletin involves modifying a wiring circuit for the PCM by grounding PCM cavity # 56 to prevent it from setting a power steering fault. MANUAL TRANSMISSION EQUIPPED VEHICLES WITHOUT HEATED REAR WINDOW. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Following the procedure outlined in the Service Manual remove the Powertrain Control Module (PCM). 3. Locate and remove the wire dress shield and red terminal locking wedges from the 60-way connector. 4. Locate cavity 56 in the 60-way rear seal retainer (cover). Lightly center punch a dimple in the round recess in the plastic. 5. Carefully drill through the cover with a # 27 or 9/64" drill. (Apply tape to the drill bit 0.1" above the tip as a drill stop). CAUTION: DRILLING TOO DEEP WILL DAMAGE THE SEAL AND TERMINAL LOCKING FINGER. DEPTH OF PLASTIC TO BE REMOVED IS 1/32" AT THE EDGE 6. Using a paper clip or similar device, push the plastic plug out through the terminal cavity. 7. Install the female terminal of wiring assembly P/N 4796589 into the cavity. (Make sure the terminal is fully locked) 8. Route the new wire along with the existing wires. Spot-tape the new wire to the harness to within one inch of the 60-way connector. 9. Install the locking wedges and wire dress shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 181594 > Aug > 94 > PCM - MIL ON/DTC 65 Set > Page 7638 10. Install the PCM with the eyelet of wiring assembly P/N 4796589 under the lower rear screw. Tighten the mounting screws to 40 to 50 in.lbs. Do not exceed 50 in.lbs. 11. Connect the battery negative cable. AUTOMATIC TRANSMISSION EQUIPPED VEHICLES AND MANUAL TRANSMISSION VEHICLES WITH HEATED REAR WINDOWS. 1. Turn the ignition key to the off position. Disconnect the negative battery cable. 2. Plug wiring jumper P/N 4793069 into the power steering switch connector (C109 in the wiring diagrams). The switch connector is located at the end of the wiring take-out -- taped to the main wiring harness six inches forward of the main engine compartment wiring grommet. 3. Connect the battery negative cable. ALL VEHICLES SERVICED UNDER THIS BULLETIN: To check the repair, use the DRB III to check the power steering switch state. It should show the switch closed (pressure low) condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-72-90 Manual Transmission Equipped, W/0 Heated Rear Window 0.6 Hrs. 08-80-72-91 Automatic & Manual Transmission Equipped With Heated Rear Window 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7643 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7644 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7645 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7646 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7651 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7652 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7653 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7654 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering Pressure Switch Service Manual Revision NO: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 SUBJECT: Service Manual Revision - Power Steering Pressure Switch Service MODELS: 1995 (PL) Neon DISCUSSION: This Technical Service Bulletin contains revised service manual pages. The revisions are marked with "ASTERISKS". Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7660 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7661 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7662 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 190294 > Feb > 94 > Power Steering Pressure Switch - Service Manual Revision > Page 7663 Please insert the revised service manual pages in the appropriate service manual. MANUAL TITLE PUBLICATION NO. PAGES CHANGE 1995 Neon 81-270-5025 19-9 Power Steering through Pressure Switch 19-12 Installation POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision Power Steering Pressure Switch: All Technical Service Bulletins Power Steering - Pressure Switch Installation Revision NUMBER: 19-02-94 GROUP: Steering DATE: Feb. 25, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1995 Neon - Publication No. 81-270-5025 DESCRIPTION OF CHANGE Power Steering Pressure Switch Installation Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7668 19-9 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7669 19-10 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7670 19-11 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pressure Switch: > 19-02-94 > Feb > 94 > Power Steering - Pressure Switch Installation Revision > Page 7671 19-12 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 7674 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 7675 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Power Steering Pressure Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Power Steering Pressure Switch Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Operation Fig. 15 Power Steering Pressure Switch PURPOSE The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The pressure sensing switch is located in the power steering gear. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure Switch Operation > Page 7697 Power Steering Pressure Switch: Description and Operation Power Steering Switch Failure NAME OF CODE: Power Steering Switch Failure WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: With the vehicle above 40 mph for more than 30 seconds, the power steering pressure switch remains closed. THEORY OF OPERATION: The PCM monitors the power steering pressure switch for a high pressure condition. The power steering pressure switch signals the PCM whenever there is a power steering load (pressure exceeding 500 psi). During this condition, the PCM will adjust the rpm to prevent a possible stall. the power steering pressure switch is a normally open switch. POSSIBLE CAUSES: - PCM failure - Connector terminals or wires Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7704 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN SWITCH The Key-IN chime is used to indicate to the operator that the key is in the ignition with the driver's door open. If the key is in the ignition and the driver's door is open, a ground path is completed from the G26 circuit at the cluster, through the closed Key-IN switch, to the G16 circuit, and terminating at the door ajar switch, which is case-grounded. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 190594 > May > 94 > Steering Column - Clicking Noise When Turning Steering Column Lock: Customer Interest Steering Column - Clicking Noise When Turning NO: 19-05-94 GROUP: Steering DATE: May 20, 1994 SUBJECT: Clicking Noise In Steering Column MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 3/22/94, (MDH 03-22-XX). SYMPTOM/CONDITION: Clicking noise in upper steering column area when turning steering wheel. PARTS REQUIRED: 1 4202151 Shim REPAIR PROCEDURE: This bulletin involves installing a shim under the rear boss of the steering column lock housing. 1. Remove the upper and lower column shrouds as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 19-37). Remove the screws in the turn signal and wiper switch and set the switches aside to gain access to the lock housing safety screws. 2. Loosen the two safety screws which secure the lock housing to the column jacket using a # 27 Torx bit. Do not remove the screws. Refer to Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 190594 > May > 94 > Steering Column - Clicking Noise When Turning > Page 7716 3. Insert shim P/N 4202151 under the rear screw boss in the lockhousing. Refer to Figure 2. 4. Tighten the two safety screws on the lockhousing to 85 In.Lbs. (9 N-m). 5. Reinstall the turn signal and wiper switches. 6. Reinstall the upper and lower column shrouds removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-90 0.3 Hrs. FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 190594 > May > 94 > Steering Column - Clicking Noise When Turning Steering Column Lock: All Technical Service Bulletins Steering Column - Clicking Noise When Turning NO: 19-05-94 GROUP: Steering DATE: May 20, 1994 SUBJECT: Clicking Noise In Steering Column MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 3/22/94, (MDH 03-22-XX). SYMPTOM/CONDITION: Clicking noise in upper steering column area when turning steering wheel. PARTS REQUIRED: 1 4202151 Shim REPAIR PROCEDURE: This bulletin involves installing a shim under the rear boss of the steering column lock housing. 1. Remove the upper and lower column shrouds as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 19-37). Remove the screws in the turn signal and wiper switch and set the switches aside to gain access to the lock housing safety screws. 2. Loosen the two safety screws which secure the lock housing to the column jacket using a # 27 Torx bit. Do not remove the screws. Refer to Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 190594 > May > 94 > Steering Column - Clicking Noise When Turning > Page 7722 3. Insert shim P/N 4202151 under the rear screw boss in the lockhousing. Refer to Figure 2. 4. Tighten the two safety screws on the lockhousing to 85 In.Lbs. (9 N-m). 5. Reinstall the turn signal and wiper switches. 6. Reinstall the upper and lower column shrouds removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-90 0.3 Hrs. FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: Customer Interest Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: All Technical Service Bulletins Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Power Steering Gear Steering Gear: Specifications Power Steering Gear Outer Tie Rod End Locknut ................................................................................................................. ...................................................................... 45 ft-lbs Power Steering Hose Tube Nuts .................... ............................................................................................................................................................ 22 ft-lbs Power Steering Pump Relief Valve Ball Seat ............................................................................................................................................................ 48 in-lbs Pressure Hose Banjo Bolt ..................................................................................................... ..................................................................................... 25 ft-lbs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Power Steering Gear > Page 7738 Steering Gear: Specifications Manual Steering Gear Inner-To-Outer Tie Rod Jam Nut ......................................................................................................... ..................................................................... 45 ft-lbs Tie Rod End To Steering Knuckle Nut ............. ........................................................................................................................................................ 45 ft-lbs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7739 Steering Gear: Adjustments The rack and pinion power steering gear used on these models should not be serviced or adjusted. If a malfunction or oil leak should occur, the complete steering gear should be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service Steering Gear: Service and Repair Manual Steering Gear Service The manual steering gear assembly should not be serviced or adjusted. In the event of damage or a malfunction such as an oil leak, the entire assembly should be replaced. However, the inner tie rod boots and outer tie rod ends can be replaced as follows: 1. Loosen inner to outer tie rod jam nut; then, if assembly is still in vehicle, remove nut securing outer tie rod end to steering knuckle. 2. Separate outer tie rod from steering knuckle using remover tool No. MB990635, or equivalent, then expand tie rod boot to inner tie rod clamp using suitable pliers. 3. Remove clamp from steering gear boot, then expand boot snorkel clamp using suitable pliers. 4. Slip clamp from boot, then remove inner tie rod boot to steering gear clamp. 5. Using a small screwdriver, gently lift lip of inner tie rod boot out of retaining groove in steering gear, then remove boot from gear. 6. Reverse procedure to install, noting the following: a. Lubricate inner tie rod boot groove and boot end seal with suitable silicone lubricant. b. Tighten inner to outer tie rod jam nut and outer tie rod end to steering knuckle nut to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 7742 Steering Gear: Service and Repair Steering Gear Replacement Manual Steering Gear Replacement Manual Steering Gear Assembly 1. Disconnect steering gear coupler from steering column shaft coupler. 2. Raise and support vehicle, then remove both front wheel and tire assemblies. 3. Remove engine/transaxle dampener. 4. Remove attaching nuts from both tie rod ends. 5. Remove both tie rod end studs from steering knuckle using remover tool No. MB-990635, or equivalent, then disconnect wiring harness connector from power steering fluid pressure switch. 6. Remove power steering pressure and return hose routing bracket from front suspension crossmember. 7. Remove power steering fluid, pressure and return hoses from power steering gear assembly. 8. Scribe a line marking the location of where front suspension crossmember is mounted against body. 9. Position a transaxle jack beneath the center of the front suspension crossmember, then remove two bolts attaching front suspension crossmember to frame rails of vehicle. 10. Loosen both rear bolts and lower control arm to body of vehicle. 11. Using transaxle jack lower front suspension crossmember enough to allow steering gear to be removed. 12. Remove four bolts attaching steering gear assembly to front suspension crossmember, then the steering gear assembly. 13. Reverse procedure to install. Power Steering Gear Replacement Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 7743 Power Steering Gear Assembly 1. Disconnect steering gear coupler from steering column shaft coupler. 2. Raise and support vehicle, then remove both front wheel and tire assemblies. 3. Remove engine/transaxle dampener. 4. Remove attaching nuts from both tie rod ends. 5. Remove both tie rod end studs from steering knuckle using remover tool No. MB-990635, or equivalent, then disconnect wiring harness connector from power steering fluid pressure switch. 6. Remove power steering pressure and return hose routing bracket from front suspension crossmember. 7. Remove power steering fluid, pressure and return hoses from power steering gear assembly. 8. Scribe a line marking the location of where front suspension crossmember is mounted against body. 9. Position a transaxle jack beneath the center of the front suspension crossmember, then remove two bolts attaching front suspension crossmember to frame rails of vehicle. 10. Loosen both rear bolts and lower control arm to body of vehicle. 11. Using transaxle jack lower front suspension crossmember enough to allow steering gear to be removed. 12. Remove four bolts attaching steering gear assembly to front suspension crossmember, then the steering gear assembly. 13. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls for Steering Shaft Coupler: > NHTSA97V169000 > Oct > 97 > Recall 97V169000: Steering Column Coupler May Disconnect Steering Shaft Coupler: Recalls Recall 97V169000: Steering Column Coupler May Disconnect The steering column coupler can become disconnected when the vehicle experiences an underbody impact. Loss of steering control can occur. Dealers will replace the steering column coupler with a coupler design that collapses on impact. Owner notification is expected to begin during November 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > NHTSA97V169000 > Oct > 97 > Recall 97V169000: Steering Column Coupler May Disconnect Steering Shaft Coupler: All Technical Service Bulletins Recall 97V169000: Steering Column Coupler May Disconnect The steering column coupler can become disconnected when the vehicle experiences an underbody impact. Loss of steering control can occur. Dealers will replace the steering column coupler with a coupler design that collapses on impact. Owner notification is expected to begin during November 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle > Page 7765 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle > Page 7771 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7772 Steering Wheel: Service and Repair 1. Disconnect battery ground cable. 2. Place front wheels straight forward. 3. Rotate steering wheel 180° clockwise. 4. Lock steering with column lock cylinder. 5. Remove speed control switch and connector. 6. Remove air bag module attaching bolts from rear of steering wheel. 7. Lift module and disconnect wiring. 8. Remove steering wheel retaining nut and vibration damper if equipped. 9. With appropriate tool, remove steering wheel while avoiding damage to clockspring wiring. 10. Reverse procedure to install, noting the following: a. Install steering wheel ensuring flats on hub align with clockspring. b. Torque steering wheel mounting nut to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair 1. Loosen jam nut, then disconnect tie rod from steering knuckle. 2. Remove outer tie rod and jam nut, then the outer boot clamp. 3. Use pliers to expand boot snorkel clamp, then slide clamp onto breather tube. 4. Remove inner boot clamp, then mark breather tube location and remove boot. 5. Reverse procedure to install, noting the following: a. Line up mark and breather tube location. b. Install boot over housing lip with hole in boot aligned with breather tube. c. Lubricate outer boot groove with silicone prior to installing outer boot clamp and ensure boot is not twisted. d. Tighten tie rod jam nut to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod Torque Tie Rod Torque Tie Rod End Attaching Nut 61 Nm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 7780 Tie Rod End: Service and Repair 1. Loosen jam nut, then disconnect tie rod from steering knuckle. 2. Remove outer tie rod and jam nut, then the outer boot clamp. 3. Use pliers to expand boot snorkel clamp, then slide clamp onto breather tube. 4. Remove inner boot clamp, then mark breather tube location and remove boot. 5. Reverse procedure to install, noting the following: a. Line up mark and breather tube location. b. Install boot over housing lip with hole in boot aligned with breather tube. c. Lubricate outer boot groove with silicone prior to installing outer boot clamp and ensure boot is not twisted. d. Tighten tie rod jam nut to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint Ball Joint Wear Inspection With weight of vehicle resting on wheel, grasp grease fitting and with no mechanical assistance or added force, attempt to move grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of ball joint is recommended. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 7786 Ball Joint: Testing and Inspection Upper Ball Joint Ball Joint Wear Inspection With weight of vehicle resting on wheel, grasp grease fitting and with no mechanical assistance or added force, attempt to move grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of ball joint is recommended. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement 1. Remove lower control arm following procedure outlined under Control Arm/ Control Arm Replacement. 2. Using screwdriver or other suitable tool, pry ball joint seal boot off ball joint assembly. 3. Position receiving cup tool No. 6758, or equivalent, to support lower control arm while receiving ball joint assembly. 4. Install receiver/installer tool No. 6804, or equivalent, in top of ball joint assembly. 5. Using suitable press, press ball joint assembly completely out of control arm. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 7789 Ball Joint: Service and Repair Upper Ball Joint Replacement 1. Remove lower control arm following procedure outlined under Control Arm/ Control Arm Replacement. 2. Using screwdriver or other suitable tool, pry ball joint seal boot off ball joint assembly. 3. Position receiving cup tool No. 6758, or equivalent, to support lower control arm while receiving ball joint assembly. 4. Install receiver/installer tool No. 6804, or equivalent, in top of ball joint assembly. 5. Using suitable press, press ball joint assembly completely out of control arm. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Control Arm Bushing: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7799 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 7800 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Control Arm Bushing: Customer Interest Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 7805 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 7806 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 7807 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 7808 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration Control Arm Bushing: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 7814 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 7815 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 220195 > Jan > 95 > Control Arm Bushings Steering Wheel Oscillation Control Arm Bushing: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 220195 > Jan > 95 > Control Arm Bushings Steering Wheel Oscillation > Page 7820 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 220195 > Jan > 95 > Control Arm Bushings Steering Wheel Oscillation > Page 7821 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 220195 > Jan > 95 > Control Arm Bushings Steering Wheel Oscillation > Page 7822 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 220195 > Jan > 95 > Control Arm Bushings Steering Wheel Oscillation > Page 7823 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Arm Bushing: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shift Cable: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Arm Bushing: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear Shift Cable: All Technical Service Bulletins M/T - Gear Shift Lever/Knob Vibration In 3RD Gear NO: 21-11-94 GROUP: Transmission DATE: May 27, 1994 SUBJECT: Manual Transmission Gear Shift Knob Vibration and Shift Cable Buzz MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APR. 12, 1994 (MDH 04-12-XX) AND EQUIPPED WITH A MANUAL TRANSMISSION. SYMPTOM/CONDITION: Vibration felt through the gear shift knob while operating the vehicle in 3rd gear. May be accompanied by a buzzing sound coming from the lower center of the instrument panel or console. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) with the appropriate diagnostic procedure manual to verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the repair. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves removing the transmission assembly from the vehicle and replacing the 3rd input gear, the 3/4 synchronizer assembly, and tie strapping the shift cables. 1. Follow the procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025) for the NV T350 (A-578) Manual Transaxle, Pages 21-7 & 21-8, and remove the Transaxle from the vehicle. 2. Starting on Page 21-9 and continuing through Page 21-16 of the Neon Service Manual, disassemble the Transaxle down to and including disassembly of the Input Shaft Assembly. 3. Starting on Page 21-24 of the Neon Service Manual, reassemble the Input Shaft Assembly using the new 3rd Speed Gear and 3/4 Synchronizer Assembly provided in the repair package. Also, do not re-use the Snap Rings removed during disassembly. Select the thickest Snap Ring supplied in the repair package that will fully fit in the 3/4 and 5/R Synchronizer Hub Snap Ring grooves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Arm Bushing: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 7833 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Arm Bushing: > 211194 > May > 94 > M/T - Gear Shift Lever/Knob Vibration In 3RD Gear > Page 7843 4. Complete the reassembly of the Transaxle following the instructions listed on Page 21-27. Use new Roll Pins supplied in the repair package when assembling the Crossover and Selector Levers to the Transaxle. While still on the bench, make sure that all gears can be selected and the Transaxle is functioning properly. 5. Install the Transaxle into the vehicle. Fill the Transaxle with Mopar Manual Transaxle Fluid (MS 9417) P/N 4773167. Use of other type fluids could result in hard shifting, gear or Synchronizer failure. 6. Install the Transmission Shift Cables to the Transaxle Bracket using the two new Clips (P/N 4269830). Install Tie Strap (P/N 6015756) 7" forward of the Cable Routing Clip (See Illustration). Pull the Tie Strap tight enough to make the Cable Foam Sleeves contact each other. Clip off the excess Tie Strap lead. 7. Perform the Gearshift Cable Crossover Adjustment following the procedure outlined in the Service Manual on Page 21-4. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-32-22-91 4.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 7852 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps > Page 7858 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Ball Stud: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 7867 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Customer Interest: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 7868 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Ball Stud: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 7874 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 7875 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions Ball Stud: All Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7880 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7881 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7882 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7883 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7884 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions Ball Stud: All Technical Service Bulletins Drivetrain/Brakes - Service Manual Revisions NUMBER: 26-01-95 GROUP: Miscellaneous DATE: Feb. 1995 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1995 Neon - Publication Number 81-270-5025 PAGES DESCRIPTION OF CHANGES Major revisions to the driveshaft Service Procedures Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7890 2 - 40 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7891 2 - 41 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7892 2 - 42 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7893 2 - 43 Torque Specs (Brake Caliper to Steering Knuckle bolts - 23 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Stud: > 26-01-95 > Feb > 95 > Drivetrain/Brakes - Service Manual Revisions > Page 7894 2 - 68 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Technical Service Bulletins > Page 7895 Ball Stud: Service and Repair 1. Remove cotter pin, castle nut and hub nut while vehicle is still on floor with brakes applied. 2. Raise and support vehicle, then remove front tire and wheel assembly. 3. Remove front disc brake caliper and place aside. CAUTION: Do not let caliper assembly hang by hose. 4. Remove front disc brake, then disconnect tie rod from steering knuckle using removal tool No. MB-990635, or equivalent. 5. Separate ball joint stud from steering knuckle by prying down on lower control arm. Ensure ball joint seal is not damage. 6. Pull steering knuckle assembly out and away from outer CV joint of driveshaft assembly. 7. Remove two steering knuckle to strut damper attaching bolts, then the steering knuckle and hub/bearing assembly from vehicle. 8. Reverse procedure to install. Torque clamp bolt to 70 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair Lateral Stabilizer Rod: Service and Repair Rear suspension lateral link bushings are not replaceable. Lateral links are serviced as a unit. The lateral links are not interchangeable. The forward link is non adjustable, both bushings sleeves are the same size. The rearward link is adjustable, the small bushing sleeve must be placed at the spindle knuckle to allow toe adjustments. 1. Raise and support vehicle, then remove rear wheels. 2. Remove lateral link attachment bolt and washers at the spindle knuckle. 3. Remove lateral link attachment bolt, washers and adjustment cams at the cross member, then remove lateral links. 4. Reverse procedure to install, noting the following: a. Tighten nuts and bolts to specifications. b. Forward lateral links have same size bushing sleeves at each end. c. Rearward lateral links have two different size bushing sleeves, small bushing sleeve must be installed at spindle knuckle end. d. The short mounting bolt is used at the spindle knuckle end, and must be installed with head of bolt towards front of vehicle. e. The long mounting bolt is used at the crossmember end, and must be installed with head of bolt towards rear of vehicle. f. Lateral link bolts must be tightened to specification with suspension supporting vehicle weight. g. Check and adjust rear wheel alignment as outlined under Wheel Alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes Rear Knuckle: Service and Repair With Rear Drum Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove brake support plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. CAUTION: Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. NOTE: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7903 Tension Strut Removal 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7904 Rear Knuckle: Service and Repair With Rear Disc Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove disc brake adapter plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. CAUTION: Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. CAUTION: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7905 Tension Strut Removal 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes Spindle: Service and Repair With Rear Drum Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove brake support plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Tension Strut Removal Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7910 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings e. Refer to image when installing tension strut retainer washers and bushings. f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7911 Spindle: Service and Repair With Rear Disc Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove disc brake adapter plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. Do not allow assembly to hang from the brake fluid hose. 4. On all models, loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Tension Strut Removal Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 7912 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings e. Refer to image when installing tension strut retainer washers and bushings. f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair Stabilizer Bar: Service and Repair 1. Raise and support vehicle, then remove both rear wheels. 2. Disconnect roll bar from attaching links at each side, then swing bar down to clear links. 3. Remove bolts from roll bar attaching brackets, then remove roll bar from vehicle. 4. Reverse procedure to install, noting the following: a. Tighten nuts and bolts to specifications. b. Ensure slit in roll bar bushings face rear of vehicle when installed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 7924 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise Suspension Spring ( Coil / Leaf ): Customer Interest Front Coil Spring - Metallic Click Noise NO: 02-02-95 GROUP: Suspension DATE: Feb. 10, 1995 SUBJECT: Front Coil Spring Click MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO OCT. 3, 1994 (MDH 1O-03-XX). SYMPTOM/CONDITION: Customer complaint of a metallic click coming from either front strut assembly. The noise can occur when driving over bumpy road surfaces, but typically can be noticed over roads with medium to large bumps. The noise should be more detectable at speeds around 30 MPH. This noise should not be confused with a power steering system rattle which transmits through the steering column or front fender inner splash shield rattles. DIAGNOSIS: Inspect left and right front coil springs for signs of contact between the first and second coils from the top of the springs. It may be necessary to remove the front strut assembly to sufficiently inspect the coil spring. If contact is noted, proceed to the repair procedure. PARTS REQUIRED: AR 5273401 Front Coil Spring Assembly (with tag I.D. 401) AR 5273402 Front Coil Spring Assembly (with tag I.D. 402) AR 5273403 Front Coil Spring Assembly (with tag I.D. 403) AR 5273404 Front Coil Spring Assembly (with tag I.D. 404) AR 5273405 Front Coil Spring Assembly (with tag I.D. 405) AR 5273406 Front Coil Spring Assembly (with tag I.D. 406) AR 5273407 Front Coil Spring Assembly (with tag I.D. 407) AR 5273408 Front Coil Spring Assembly (with tag I.D. 408) AR 5273409 Front Coil Spring Assembly (with tag I.D. 409) AR 5273411 Front Coil Spring Assembly (with tag I.D. 411) AR 5273412 Front Coil Spring Assembly (with tag I.D. 412) AR 5273413 Front Coil Spring Assembly (with tag I.D. 413) AR 5273414 Front Coil Spring Assembly (with tag I.D. 414) AR 5273415 Front Coil Spring Assembly (with tag I.D. 415) AR 5273416 Front Coil Spring Assembly (with tag I.D. 416) AR 5273417 Front Coil Spring Assembly (with tag I.D. 417) NOTE: THE FRONT COIL SPRING CAN BE IDENTIFIED BY A TAPE LABEL I.D. TAG LOCATED APPROXIMATELY ON THE MIDDLE COIL. IT WILL HAVE THE LAST THREE DIGITS OF THE PART NUMBER NEEDED TO IDENTIFY THE CORRECT REPLACEMENT SPRING. THE NEW COIL SPRING CAN BE IDENTIFIED BY THE ADDITION OF A POLYURETHANE SLEEVE BETWEEN THE TOP TWO COILS. REPAIR PROCEDURE: This bulletin involves replacing one or both front coil springs. 1. Replace the affected front coil spring(s) as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 2-10 through 2-15, with the correct part number called out in the Parts Required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Spring, Front Coil, Inspect and Replace, One Side Labor Operation No: 02-27-01-98 ......................................................................................................................................... ................................ 0.6 Hrs. Spring, Front Coil, Inspect and Replace, Both Sides Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise > Page 7929 02-27-01-99 ......................................................................................................................................... ................................ 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 7935 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Coil Spring - Metallic Click Noise NO: 02-02-95 GROUP: Suspension DATE: Feb. 10, 1995 SUBJECT: Front Coil Spring Click MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO OCT. 3, 1994 (MDH 1O-03-XX). SYMPTOM/CONDITION: Customer complaint of a metallic click coming from either front strut assembly. The noise can occur when driving over bumpy road surfaces, but typically can be noticed over roads with medium to large bumps. The noise should be more detectable at speeds around 30 MPH. This noise should not be confused with a power steering system rattle which transmits through the steering column or front fender inner splash shield rattles. DIAGNOSIS: Inspect left and right front coil springs for signs of contact between the first and second coils from the top of the springs. It may be necessary to remove the front strut assembly to sufficiently inspect the coil spring. If contact is noted, proceed to the repair procedure. PARTS REQUIRED: AR 5273401 Front Coil Spring Assembly (with tag I.D. 401) AR 5273402 Front Coil Spring Assembly (with tag I.D. 402) AR 5273403 Front Coil Spring Assembly (with tag I.D. 403) AR 5273404 Front Coil Spring Assembly (with tag I.D. 404) AR 5273405 Front Coil Spring Assembly (with tag I.D. 405) AR 5273406 Front Coil Spring Assembly (with tag I.D. 406) AR 5273407 Front Coil Spring Assembly (with tag I.D. 407) AR 5273408 Front Coil Spring Assembly (with tag I.D. 408) AR 5273409 Front Coil Spring Assembly (with tag I.D. 409) AR 5273411 Front Coil Spring Assembly (with tag I.D. 411) AR 5273412 Front Coil Spring Assembly (with tag I.D. 412) AR 5273413 Front Coil Spring Assembly (with tag I.D. 413) AR 5273414 Front Coil Spring Assembly (with tag I.D. 414) AR 5273415 Front Coil Spring Assembly (with tag I.D. 415) AR 5273416 Front Coil Spring Assembly (with tag I.D. 416) AR 5273417 Front Coil Spring Assembly (with tag I.D. 417) NOTE: THE FRONT COIL SPRING CAN BE IDENTIFIED BY A TAPE LABEL I.D. TAG LOCATED APPROXIMATELY ON THE MIDDLE COIL. IT WILL HAVE THE LAST THREE DIGITS OF THE PART NUMBER NEEDED TO IDENTIFY THE CORRECT REPLACEMENT SPRING. THE NEW COIL SPRING CAN BE IDENTIFIED BY THE ADDITION OF A POLYURETHANE SLEEVE BETWEEN THE TOP TWO COILS. REPAIR PROCEDURE: This bulletin involves replacing one or both front coil springs. 1. Replace the affected front coil spring(s) as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 2-10 through 2-15, with the correct part number called out in the Parts Required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Spring, Front Coil, Inspect and Replace, One Side Labor Operation No: 02-27-01-98 ......................................................................................................................................... ................................ 0.6 Hrs. Spring, Front Coil, Inspect and Replace, Both Sides Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise > Page 7940 02-27-01-99 ......................................................................................................................................... ................................ 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 021194 > Aug > 94 > Rear Suspension - Harsh Ride on Bumpy Roads Suspension Strut / Shock Absorber: Customer Interest Rear Suspension - Harsh Ride on Bumpy Roads NO: 02-11-94 GROUP: Suspension DATE: Aug. 5, 1994 SUBJECT: Harsh Ride MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 6/10/94, (MDH 06-10-XX), WITHOUT SALES CODE ACR. SYMPTOM/CONDITION: Owner complains of harsh, rough, or choppy ride when vehicle is driven on roads having small to medium surface irregularities or expansion joints. PARTS REQUIRED: 2 4626992 Rear Strut Dampers Assemblies REPAIR PROCEDURE: This bulletin involves replacing both rear strut damper assemblies with revised parts. 1. Install new rear strut damper assemblies, P/N 4626992, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 2-54 to 2-56. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-11-91 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 021094 > Aug > 94 > Rear Suspension - Frequent Bottoming Suspension Strut / Shock Absorber: Customer Interest Rear Suspension - Frequent Bottoming NO: 02-10-94 GROUP: Suspension DATE: Aug. 5, 1994 SUBJECT: Rear Suspension Bottoming MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 5/25/94, (MDH 05-25-XX). SYMPTOM/CONDITION: Owner complains of frequent rear suspension bottoming with four passengers when vehicle is driven over road surfaces with large potholes or other severe depressions. DIAGNOSIS: Inspect both rear strut assemblies and confirm that they are correctly assembled as shown in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 2-53. If each strut is correctly assembled, perform the following repair procedure. PARTS REQUIRED: 2 4626757 Rear Strut Damper Spring Insulator REPAIR PROCEDURE: This bulletin involves adding an additional spring insulator on each rear strut damper assembly. 1. Remove and disassemble each rear suspension strut as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 2-54 to 2-60. 2. Add an additional rear strut damper spring insulator, P/N 4626757, on each rear strut damper. 3. Assemble each rear strut damper and install each assembly into vehicle following the same procedure in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-11-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Suspension Strut / Shock Absorber: All Technical Service Bulletins Alignment & Suspension Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 7958 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 021194 > Aug > 94 > Rear Suspension - Harsh Ride on Bumpy Roads Suspension Strut / Shock Absorber: All Technical Service Bulletins Rear Suspension - Harsh Ride on Bumpy Roads NO: 02-11-94 GROUP: Suspension DATE: Aug. 5, 1994 SUBJECT: Harsh Ride MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 6/10/94, (MDH 06-10-XX), WITHOUT SALES CODE ACR. SYMPTOM/CONDITION: Owner complains of harsh, rough, or choppy ride when vehicle is driven on roads having small to medium surface irregularities or expansion joints. PARTS REQUIRED: 2 4626992 Rear Strut Dampers Assemblies REPAIR PROCEDURE: This bulletin involves replacing both rear strut damper assemblies with revised parts. 1. Install new rear strut damper assemblies, P/N 4626992, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 2-54 to 2-56. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-11-91 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 021094 > Aug > 94 > Rear Suspension - Frequent Bottoming Suspension Strut / Shock Absorber: All Technical Service Bulletins Rear Suspension - Frequent Bottoming NO: 02-10-94 GROUP: Suspension DATE: Aug. 5, 1994 SUBJECT: Rear Suspension Bottoming MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 5/25/94, (MDH 05-25-XX). SYMPTOM/CONDITION: Owner complains of frequent rear suspension bottoming with four passengers when vehicle is driven over road surfaces with large potholes or other severe depressions. DIAGNOSIS: Inspect both rear strut assemblies and confirm that they are correctly assembled as shown in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 2-53. If each strut is correctly assembled, perform the following repair procedure. PARTS REQUIRED: 2 4626757 Rear Strut Damper Spring Insulator REPAIR PROCEDURE: This bulletin involves adding an additional spring insulator on each rear strut damper assembly. 1. Remove and disassemble each rear suspension strut as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 2-54 to 2-60. 2. Add an additional rear strut damper spring insulator, P/N 4626757, on each rear strut damper. 3. Assemble each rear strut damper and install each assembly into vehicle following the same procedure in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-11-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Suspension Strut / Shock Absorber: All Technical Service Bulletins Alignment & Suspension Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 7972 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front Disassembly/Assembly 1. Clamp strut assembly by the clevis bracket into suitable vise. Coil Spring Removal 2. Scribe coil spring and strut assembly right or left, then using compressor tool No. C-4838, or equivalent, compress coil spring. 3. Install socket strut nut tool No. L4558A, or equivalent, on strut shaft retaining nut. 4. Install 10 mm socket on hex head of strut shaft and remove nut while holding strut to keep from rotating. 5. Remove upper spring seat, pivot bearing and dust shield as an assembly. 6. Remove coil spring. 7. Reverse procedure to install. With ABS 1. Loosen wheel lug nuts, then raise and support vehicle. 2. Remove wheel and tire assembly, then disconnect the hydraulic brake hose routing bracket from strut bracket. 3. Speed sensor is combined with hydraulic hose routing bracket. 4. Remove two strut assembly clevis bracket to steering knuckle attaching bolts. 5. Remove three nuts attaching strut assembly upper mount to shock tower, then the strut. 6. Reverse procedure to install. Without ABS 1. Loosen wheel lug nuts, then raise and support vehicle. 2. Remove wheel and tire assembly, then disconnect the hydraulic brake hose routing bracket from strut bracket. 3. Remove two strut assembly clevis bracket to steering knuckle attaching bolts. 4. Remove three nuts attaching strut assembly upper mount to shock tower, then the strut. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 7975 Suspension Strut / Shock Absorber: Service and Repair Rear Replacement 1. Raise and support vehicle, then remove wheel. 2. Remove brake fluid hose support bracket from strut. 3. On models equipped with ABS, remove speed sensor cable and routing clip from strut. 4. On all models, Loosen but do not remove spindle knuckle to strut clevis bolts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. CAUTION: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. 5. Lower vehicle, then access four upper strut to strut tower mounting nuts. Removing carpeting and dust shield as necessary. 6. Loosen but do not remove upper strut to tower mounting nuts. 7. Using a suitable device, support suspension. CAUTION: Do not allow suspension components to hang after removing strut. Do not place support under lateral links or tension strut as they may bend. 8. Remove previously loosened upper strut mounting nuts and strut to spindle knuckle bolts. 9. Slide strut straight back off spindle knuckle, then lower strut from vehicle. 10. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts, tighten by turning nuts only. c. Check and adjust rear wheel alignment as outlined under Wheels, Suspension/ Tires and Alignment/ Wheel/ Wheel Alignment. Strut Service Coil springs on this vehicle are available in different load rates. Spring rates may be different on each side of the vehicle depending on how the vehicle is equipped. Ensure correct spring rates are chosen during assembly. The gas-charged strut damper cannot be rebuilt and is serviced as a unit. 1. Remove strut assembly as outlined under Strut Replacement. 2. Using a suitable marker or paint, place match marks on components of strut assembly to aid in assembly alignment. Strut Assembly Mounted In Vise 3. Place strut assembly into a suitable vise. CAUTION: Do not clamp body of strut into vise. 4. Using coil spring compressor tool No. C-4838, or equivalent, compress spring until tension is removed from upper strut mount assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 7976 Strut Shaft Nut Replacement 5. Using strut nut wrench tool No. L-4558A, or equivalent, and a 10 mm socket and breaker bar to hold strut shaft, remove strut shaft nut. Fig. 1 Exploded View Of Rear Suspension 6. Remove outer washer, upper strut mount, coil spring, inner washer, dust shield, jounce bumper and spring isolator from strut. 7. Reverse procedure to install, noting the following: a. Tighten nuts to specifications. b. Install inner strut shaft washer with raised edge up and outer strut shaft washer with raised edge down. c. Transfer alignment marks to any replaced component. Ensure alignment of all components during assembly. Tension Strut Replacement 1. Using a suitable wrench to prevent tension strut from turning, remove nuts from both ends of tension strut. 2. Remove bushings and washers from tension strut, then remove tension strut. 3. Reverse procedure to install, noting the following: a. Tighten nuts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 7977 Tension Strut Bushings b. Install tension strut bushings and washers. c. Check and adjust rear wheel alignment as outlined under Wheel Alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: Customer Interest Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 7986 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension Popping Noise on Turns Wheel Bearing: All Technical Service Bulletins Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension Popping Noise on Turns > Page 7992 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7995 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7996 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 8006 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Valve Body: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8012 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8013 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8014 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 212395A > Jan > 96 > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Nut: > 212395A > Jan > 96 > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 8024 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 8030 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift Valve Body: Customer Interest A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 8038 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 8039 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 8040 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Valve Body: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8046 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8047 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 8048 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection Valve Body: Service and Repair Cleaning and Inspection CLEANING AND INSPECTION 1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions. 2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. 3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen light, inspect bores in valve body for scores scratches, pits and irregularities. 4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. 5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling. 6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill transaxle to the proper level with ATF. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8051 Valve Body: Service and Repair Overhaul VALVE BODY RECONDITION NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only R.T.V. sealant when installing oil pan. Oil Pan Bolts Oil Pan 1. Remove or install neutral starting and back-up lamp switch. Oil Filter Screws Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8052 Oil Filter Parking Rod E-Clip Parking Rod Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8053 Valve Body Attaching Bolts Valve Body And Governor Tubes CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. Detent Spring Attaching Screw And Spring WARNING: Tag all springs as they are removed for reassembly identification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8054 Valve Body Screws Valve Body Screws Transfer Plate And Separator Plate Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8055 Steel Ball Locations Throttle Shaft E-Clip E-Clip, Washer And Oil Seal Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8056 Manual Valve Lever And Assembly Throttle Valve Lever And Assembly Manual Valve Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8057 Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8058 Governor Plugs Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Component Information > Service and Repair > Cleaning and Inspection > Page 8059 Shift And Shuttle Valve Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Tires: Customer Interest Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8069 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8070 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8071 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8072 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Tires: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8082 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8083 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8084 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8085 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Wheels: Customer Interest Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8099 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8100 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8101 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8102 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Wheels: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8112 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8113 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8114 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8115 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns Wheel Bearing: Customer Interest Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension - Popping Noise on Turns > Page 8129 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension Popping Noise on Turns Wheel Bearing: All Technical Service Bulletins Front Suspension - Popping Noise on Turns NO: 02-07-95 GROUP: Front Suspension DATE: Apr. 7, 1995 SUBJECT: Popping Noise in Front Suspension when Turning MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MARCH 20, 1995 (MDH 03-20-XX). SYMPTOM/CONDITION: Popping noise from the left, right, or both sides of the front suspension while making sharp turns at low speeds, less than 10 MPH. DIAGNOSIS: Road test the vehicle at speeds under 10 MPH in a large clear area without traffic. Turn the steering wheel to almost full lock clockwise, but not against the steering stop, while backing up the vehicle. Stop the vehicle rapidly without locking the brakes. Turn the steering wheel counterclockwise to almost full lock position while slowly moving the vehicle forward. Stop the vehicle rapidly without locking the brakes. If a popping noise is not heard, repeat the above maneuvers except turn the steering wheel counterclockwise while backing and clockwise when going forward. This diagnosis may have to be repeated several times on some vehicles to create the noise condition. If the popping noise is heard, proceed to the repair procedure. If the popping noise is not heard, some other noise may have been present and further diagnosis and repair of the front suspension may be required and will not be covered by this procedure. PARTS REQUIRED: 2 4641120 Front Wheel Bearing Assembly AR NPN Loctite Adhesive # 640 REPAIR PROCEDURE: This bulletin involves replacing both front wheel bearings with a similar part and securing the bearings to the knuckles with an adhesive 1. Remove both left and right front knuckle and wheel bearing assemblies from the vehicle. 2. Remove both left and right wheel bearing assemblies from the knuckle. 3. Clean the bore of the knuckle using a clean shop towel or rag. 4. Clean the rust preventative from the new bearing using a clean shop towel or rag. Do not use solvents. 5. Apply Loctite Adhesive # 640 to the knuckle bore from the shoulder at the bottom of the bore to just below the snap ring groove. Do not get the adhesive in the snap ring groove or on the bearing seal. 6. Install the new wheel bearings in the knuckles. Wipe any excess adhesive from the bearing and bearing seal. 7. Install the knuckle assemblies. NOTE: THE VEHICLE MAY BE MOVED A SHORT DISTANCE AND PARKED. DO NOT DRIVE THE VEHICLE ANY FURTHER UNTIL THE ADHESIVE HAS CURED FOR A MINIMUM OF TWO HOURS. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 020795 > Apr > 95 > Front Suspension Popping Noise on Turns > Page 8135 TIME ALLOWANCE: Labor Operation No: 05-15-01-90 2.1 Hrs. Front Wheel Bearing Replace - Both Sides FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8138 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8139 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise Wheel Cover: Customer Interest Wheel Cover - Clicking Noise NO: 22-05-94 GROUP: Wheels & Tires DATE: Sep. 30, 1994 SUBJECT: Wheel Cover Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO SPORT MODELS EQUIPPED WITH 14", CENTRIFUGE WHEEL COVERS BUILT PRIOR TO 5/9/94, (MDH 05-09-XX). SYMPTOM/CONDITION: A "cycling" clicking noise coming from the wheel area of the vehicle. The sound is most noticeable when the vehicle is driven at low speeds. DIAGNOSIS: Remove all four wheel covers and drive the vehicle. If the noise is eliminated, proceed with the repair procedure. PARTS REQUIRED: AR 4472591 Cover, Full Wheel, Brushed Aluminum AR 4472593 Cover, Full Wheel, White REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover - Clicking Noise > Page 8148 This bulletin involves replacing all four wheel covers with revised parts. See illustration for identification of wheel covers. Replace the wheel covers with appropriate parts, as called out in the parts required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover Clicking Noise Wheel Cover: All Technical Service Bulletins Wheel Cover - Clicking Noise NO: 22-05-94 GROUP: Wheels & Tires DATE: Sep. 30, 1994 SUBJECT: Wheel Cover Noise MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO SPORT MODELS EQUIPPED WITH 14", CENTRIFUGE WHEEL COVERS BUILT PRIOR TO 5/9/94, (MDH 05-09-XX). SYMPTOM/CONDITION: A "cycling" clicking noise coming from the wheel area of the vehicle. The sound is most noticeable when the vehicle is driven at low speeds. DIAGNOSIS: Remove all four wheel covers and drive the vehicle. If the noise is eliminated, proceed with the repair procedure. PARTS REQUIRED: AR 4472591 Cover, Full Wheel, Brushed Aluminum AR 4472593 Cover, Full Wheel, White REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220594 > Sep > 94 > Wheel Cover Clicking Noise > Page 8154 This bulletin involves replacing all four wheel covers with revised parts. See illustration for identification of wheel covers. Replace the wheel covers with appropriate parts, as called out in the parts required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 8164 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 8170 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 8171 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 203 Nm (150 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque Lug Nuts 135 Nm Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation Air Door Actuator / Motor: Description and Operation The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioned equipped vehicles. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 8180 Air Door Actuator / Motor: Service and Repair NOTE: The instrument panel must be removed from the vehicle to gain access to the recirculation door actuator. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" Recirculation Door Actuator 2. Disconnect vacuum line from actuator. 3. Remove two nuts retaining vacuum actuator to recirculation door housing. 4. Disconnect actuator from recirc. door link. 5. Remove recirculation door actuator from vehicle. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Adjustments > Mode Control Cable Adjustment A/C Heater Control: Adjustments Mode Control Cable Adjustment 1. Attach cable to actuator arm on mode door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the mode knob completely counterclockwise. 4. While holding the knob in the counterclockwise position, pull on the black casing of the mode cable. This will take up any free play in the cable and index the mode door to the mode knob. 5. Then snap the cable hold down clip into position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Adjustments > Mode Control Cable Adjustment > Page 8185 A/C Heater Control: Adjustments Temperature Control Cable Adjustment 1. Attach cable to actuator arm on temperature door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the temperature knob completely counterclockwise. 4. While holding the knob in the counterclockwise position pull on the black casing of the temperature cable. This will take up any free play in the cable and index the temperature door to the temperature knob. 5. Then snap the cable hold down clip into position. 6. Remount control. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement A/C Heater Control: Service and Repair Mode Control Cable Replacement NOTE: The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8188 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8189 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. 8. Remove cable from vehicle. INSTALLATION For installation, reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8190 A/C Heater Control: Service and Repair Temperature Control Cable Replacement NOTE: The Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8191 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > A/C Heater Control <--> [Air Door Cable, HVAC] > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8192 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. Remove control from instrument panel. 8. Remove cable from vehicle. INSTALLATION For installation reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: Customer Interest Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 8201 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: All Technical Service Bulletins Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 8207 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 8208 Blower Motor: Locations The blower motor is located on the bottom right side of the evaporator case unit housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 8209 Blower Motor: Description and Operation BLOWER MOTOR OPERATION With the ignition switch in the RUN position, power flows from the 25 amp fuse, in cavity 7 of the fuse block, to the blower motor. Blower motor speed is controlled by the fan control switch located in the instrument panel, and by the resistor block. Blower motor low-speed operation is accomplished on the C4 circuit. When the control switch is moved to the low-speed position, current flows from the C7 circuit, through the blower motor resistor, to the C4 circuit. It then flows through the blower motor switch to the Z8 circuit. The Z8 circuit terminates at a grounding point located at the instrument panel left center support. The operation of the blower motor M1 and M2 speed operations is the same as the low-speed except that circuit C5 is used for the M1 speed, and circuit C6 is used for M2 speed operation. Blower motor high-speed operation is accomplished on the C7 circuit, which supplies battery voltage directly to the blower motor There are no resistors used in the high-speed mode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Blower Motor Noise and Vibration Diagnosis Blower Motor: Testing and Inspection Blower Motor Noise and Vibration Diagnosis Blower Motor Noise/Vibration Diagnosis The resistor block supplies the blower motor with varied voltage (low and middle speeds) or battery voltage (high speed). CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed from the heater-A/C housing. Refer to the Blower Motor Vioration/Noise chart for diagnosis. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Blower Motor Noise and Vibration Diagnosis > Page 8212 Blower Motor: Testing and Inspection Blower Motor Electrical Diagnosis Blower Motor Electrical Diagnosis For Blower motor electrical diagnosis refer to the above chart and also see Diagrams/Electrial. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C Blower Motor: Service and Repair With A/C NOTE: The blower motor can be removed from the vehicle without having to remove the unit housing assembly REMOVAL 1. Remove right side scuff plate. 2. Pull back carpet. 3. Cut wheel housing silencer in line with blower motor wiring. 4. Disconnect blower motor wiring connector. 5. Right Hand Drive (RHD) vehicle remove the motor cover. Blower Motor Retaining Screws 6. Remove three blower motor retaining screws. 7. Lower blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Then tape silencer into position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C > Page 8215 Blower Motor: Service and Repair Without A/C REMOVAL 1. Disconnect blower motor wiring connector. Blower Motor Removal 2. Grasp the blower motor while pulling down tab. Turn approximately 1/8 turn counterclockwise and remove blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Resistor Block The blower motor resistor is located in the cowl, at the base of the windshield. There are two different resistor blocks depending on whether the vehicle is equipped with A/C or not. WARNING: The blower motor resistors will get hot when in use. Do not touch resistor block if the blower motor has been running. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8219 Blower Motor Resistor: Service and Repair CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed. REMOVAL 1. Remove windshield wipers. 2. Remove cowl top screen. 3. Disconnect the resistor block wiring connector. 4. Remove two resistor block retaining screws. The screw threads attaching the resistor block are not full length. It is necessary to gently pry out the resistor block while turning the screws counterclockwise enabling the threads to engages. 5. Remove resistor block from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Part 1 of 2 Compressor Clutch: Testing and Inspection Part 1 of 2 Diagnostic Chart Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Part 1 of 2 > Page 8225 Related Images Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Part 1 of 2 > Page 8226 Compressor Clutch: Testing and Inspection Part 2 of 2 Diagnostic Chart Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Part 1 of 2 > Page 8227 Related Images Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 8228 Compressor Clutch: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 8229 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 8230 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8234 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8235 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair COMPRESSOR FRONT SHAFT SEAL The compressor front shaft seal is not serviceable. If a leak is detected at the shaft seal, the compressor must be replaced as a unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair The condenser is located in front of the engine radiator. It has no serviceable parts. If damaged or leaking, the condenser assembly must be replaced. WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. 2. Remove battery support strut. 3. Remove refrigerant lines from condenser. 4. Remove upper radiator mounts. 5. Remove condenser to radiator mounting screws. 6. Tilt radiator back and remove condenser. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8248 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8249 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8250 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair Control Assembly: Service and Repair HEATER A/C CONTROL REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Using a trim stick (special tool #C-4755), gently pry up on the top cover and cluster bezel to remove. 3. Open the ash receiver. 4. Using a trim stick (special tool #C-4755), gently Pry out on the center bezel and remove. 5. Remove the six attaching screws across the forward portion of the right upper trim panel. Then pull the panel rearward to disengage the three locator pins and remove. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Page 8254 6. Reach in and disconnect the wiring connector(s) for the rear window defogger and/or fog lamp switch(s) as required. 7. If equipped with RKE, remove the two screws retaining the module and lay over the instrument cluster. 8. Gently pull on the center A/C outlet duct to remove. 9. Remove three attaching screws at corners of the control, two front retaining and one retaining from the top rear. 10. Pull the control rearward and disconnect the wiring connector. 11. Using a screwdriver, disengage the cable attachment clips. INSTALLATION 1. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 8263 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 8264 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Case: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8269 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8270 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 8276 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 8277 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts Emits Musty Odor Evaporator Case: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts Emits Musty Odor > Page 8282 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 240695A > May > 95 > Air Conditioning Ducts Emits Musty Odor > Page 8283 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8292 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8293 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8294 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8295 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8296 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8297 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8298 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8299 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8300 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8301 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8302 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8303 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Evaporator Core: Customer Interest A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 8308 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Core: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8313 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8314 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool Evaporator Core: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8319 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8325 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8326 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8327 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8328 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8329 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8330 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8331 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8332 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8333 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8334 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8335 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 8336 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Evaporator Core: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 8345 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Core: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8350 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8351 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool Evaporator Core: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8356 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack Of Cooling Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling NO.: 24-17-94 GROUP: Heater & A/C DATE: Nov. 18, 1994 SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed Displacement Compressor) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14, 1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: DISCUSSION: A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be experienced on some of the above vehicles. The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition results in the lack of cooling from the A/C system. The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when either of these conditions are caused by the PCM. It is important to perform the complete test sequence because there are other A/C clutch relay circuit components that could also cause or contribute to the condition. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack Of Cooling Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling NO.: 24-17-94 GROUP: Heater & A/C DATE: Nov. 18, 1994 SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed Displacement Compressor) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14, 1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: DISCUSSION: A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be experienced on some of the above vehicles. The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition results in the lack of cooling from the A/C system. The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when either of these conditions are caused by the PCM. It is important to perform the complete test sequence because there are other A/C clutch relay circuit components that could also cause or contribute to the condition. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8370 Evaporator Core: Service and Repair This vehicle uses an aluminum plate and fin style evaporator. It is located in the Evaporator/Blower module. The unit housing must be removed from the vehicle before beginning with this procedure. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Use this procedure if any or all of the following items require service: - Evaporator - Air inlet duct - Recirculation door - Evaporator/Blower module case DISASSEMBLE 1. Remove the clips and screws that hold the Unit Housing to the Evaporator/Blower Module. Then separate the two units. Foam Seat Removal 2. Remove the evaporator to dash panel foam seal. 3. Disconnect fin sensing switch from harness. 4. Remove upper to lower case retaining clips and screws. Case Separation 5. Separate the case halves. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8371 Evaporator Removal 6. Lift the evaporator out of the module. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Drain Tube: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8380 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8381 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 241694 > Nov > 94 > A/C Drain Tube - Water Leak In Passenger Compartment Evaporator Drain Tube: Customer Interest A/C Drain Tube - Water Leak In Passenger Compartment NO: 24-16-94 GROUP: Heater & A/C DATE: Nov. 4, 1994 SUBJECT: Water Leak in Passenger Compartment Under Instrument Panel - A/C Drain MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Water leak on passenger floor area on left hand turns. This condition is most likely to occur when the A/C system has been in operation. DIAGNOSIS: 1. Raise vehicle on a hoist to allow access to the A/C condensate drain tube. 2. Note the orientation of the A/C condensate drain tube. The drain nipple should be pointing towards the ground at the 5 o'clock position. Remove the drain tube and check for debris or restrictions. If the drain tube is clean, proceed to the repair procedure. 3. If the drain tube is restricted, clear the opening and remove any debris and install the drain tube back on the vehicle with the correct orientation. Further diagnosis will now be necessary to determine the cause for water entry into the vehicle and will not be covered in this bulletin. REPAIR PROCEDURE: This bulletin involves removing a blockage in the evaporator housing to A/C condensate drain tube nipple. 1. Insert a long narrow tool, with a hook on the forward insertion end, slowly into the A/C evaporator drain nipple. The tool can be made out of a wire type coat hanger, with a hook fabricated on one end not to exceed the diameter of the drain tube. The hook will be used to remove styrofoam liner material. 2. Force the tool carefully through the styrofoam liner that is inside the evaporator housing until the liner is punctured. Usually water will be discharged from the drain nipple NOTE: WHEN FORCING THE TOOL INTO THE EVAPORATOR HOUSING, USE CAUTION SO AS NOT TO DAMAGE THE EVAPORATOR. 3. Remove the tool while trying to remove all or any of the liner material causing the blockage. Insert and remove the tool repeatedly to remove as much of the material as possible. 4. Install the drain tube back on the vehicle with the correct orientation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Drain Tube: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8391 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8392 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 241694 > Nov > 94 > A/C Drain Tube Water Leak In Passenger Compartment Evaporator Drain Tube: All Technical Service Bulletins A/C Drain Tube - Water Leak In Passenger Compartment NO: 24-16-94 GROUP: Heater & A/C DATE: Nov. 4, 1994 SUBJECT: Water Leak in Passenger Compartment Under Instrument Panel - A/C Drain MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Water leak on passenger floor area on left hand turns. This condition is most likely to occur when the A/C system has been in operation. DIAGNOSIS: 1. Raise vehicle on a hoist to allow access to the A/C condensate drain tube. 2. Note the orientation of the A/C condensate drain tube. The drain nipple should be pointing towards the ground at the 5 o'clock position. Remove the drain tube and check for debris or restrictions. If the drain tube is clean, proceed to the repair procedure. 3. If the drain tube is restricted, clear the opening and remove any debris and install the drain tube back on the vehicle with the correct orientation. Further diagnosis will now be necessary to determine the cause for water entry into the vehicle and will not be covered in this bulletin. REPAIR PROCEDURE: This bulletin involves removing a blockage in the evaporator housing to A/C condensate drain tube nipple. 1. Insert a long narrow tool, with a hook on the forward insertion end, slowly into the A/C evaporator drain nipple. The tool can be made out of a wire type coat hanger, with a hook fabricated on one end not to exceed the diameter of the drain tube. The hook will be used to remove styrofoam liner material. 2. Force the tool carefully through the styrofoam liner that is inside the evaporator housing until the liner is punctured. Usually water will be discharged from the drain nipple NOTE: WHEN FORCING THE TOOL INTO THE EVAPORATOR HOUSING, USE CAUTION SO AS NOT TO DAMAGE THE EVAPORATOR. 3. Remove the tool while trying to remove all or any of the liner material causing the blockage. Insert and remove the tool repeatedly to remove as much of the material as possible. 4. Install the drain tube back on the vehicle with the correct orientation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8417 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8418 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 21°C (70°F) and 32°C (90°F) when testing the switch. 1. Disconnect the 3-wire connector from switch lead located behind the glove box. Fig. 2 Fin-sensing Cycling Clutch Switch Harness Connector 16 2. Test for voltage between pin #1 to pin #3 on the wire harness connector. If voltage is detected, jump pin #1 to pin #3 using a jumper wire. Compressor clutch should engage. 3. Check for voltage between pin #1 and pin #2. If no voltage is detected, check fuse and ground circuit. 4. If compressor clutch engages, test for continuity from terminal pin #1 to pin #3 of the switch lead connector. Continuity should be detected. If not, replace the Fin-sensing Cycling Clutch Switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8419 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Expansion Valve: Customer Interest A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 8428 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Expansion Valve: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 8434 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 8435 Expansion Valve: Description and Operation The expansion valve is used to meter refrigerant into the evaporator in accordance with cooling requirements. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 8436 Expansion Valve: Testing and Inspection NOTE: Expansion valve tests should be performed after compressor tests. NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. WARNING: Review Safety Precautions and Warnings Before proceding. CAUTION: The work area and vehicle must be 21 ° to 27 °C (70 ° to 85 °F) when testing expansion valve. TO TEST THE EXPANSION VALVE: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Low Pressure Cut Off Switch 2. Disconnect wire connector at low pressure cutoff switch. Using a jumper wire, jump terminals inside wire connector boot. 3. Close all doors, windows and vents to the passenger compartment. 4. Set Heater-A/C control to A/C, full heat, floor, RECIRC. and high blower. 5. Start the engine and hold the idle speed (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. 6. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 2620 kPa (140 to 380 psi). Suction (low pressure) gauge should read 103 to 2417 kPa (15 to 35 psi). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: Protect skin and eyes from contacting CO2, personal injury can result. 7. If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid C02). Do not spray refrigerant on the expansion valve for this test. Suction side low pressure should drop to 34.5 kPa (5 psi) If not, replace expansion valve. 8. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 103 to 241 kPa (15 to 35 psi). If not, replace expansion valve. 9. When expansion valve test is complete, test A/C overall performance. Refer to Testing and Inspection/Performance Test. Remove all test equipment before returning vehicle to use. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 8437 Expansion Valve: Service and Repair WARNING: The refrigeration system must be completely empty before proceeding with this operation. REMOVAL 1. Remove the boot-type wire connector from the pressure cut-off switch. Expansion Valve 2. Remove the center bolt of refrigerant line plumbing sealing plate. 3. Carefully pull the refrigerant line-sealing plate assembly from the expansion valve towards front of vehicle. Do not scratch the expansion valve sealing surfaces with pilot tubes. 4. Cover the openings on A/C line-sealing plate assembly to prevent contamination. 5. Remove two screws securing the expansion valve to the evaporator sealing plate. 6. Carefully remove valve. INSTALLATION 1. Remove and replace the aluminum gasket on the evaporator sealing plate. 2. Carefully hold the expansion valve to the evaporator sealing plate so not to scratch the sealing surface. Install two screws and tighten to 8 to 14 N.m (70 to 130 in. lbs.). 3. Remove and replace the aluminum gasket on the refrigerant line- sealing plate assembly 4. Carefully hold the refrigerant line-sealing plate assembly to the expansion valve. Install bolt and tighten to 20 to 26 N.m (170 to 230 in. lbs.). 5. Connect wires to low pressure cut-off switch. 6. Evacuate and recharge system. 7. After expansion valve is installed, system is charged, and leaks have been checked, repeat A/C performance check. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations High Pressure Relief Valve The High Pressure Safety Valve is located on the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 8444 High Pressure Safety Valve HVAC: Service and Repair WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting sae requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixtures of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. High Pressure Relief Valve 2. Rotate the high pressure relief valve counterclockwise and separate relief valve from the vehicle. INSTALLATION For installation, reverse the above procedures using a new 0-ring seal. Evacuate and charge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 8448 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode Housing Assembly HVAC: Customer Interest A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 8457 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit Air Whistle During Fresh Air Mode Housing Assembly HVAC: All Technical Service Bulletins A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit Air Whistle During Fresh Air Mode > Page 8463 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly Use this procedure if any or all of the following items require service: - Heater core - Temperature door - Mode door - Heat/Defrost door - Assembly housing The unit housing must be removed from the vehicle before beginning with this procedure. DISASSEMBLE For Right Hand Drive (RHD) vehicles, the Unit Housing does not separate. It is a one piece unit and must be replaced as a whole. Air Distribution Module Separation 1. Remove the clips and screws that hold the Air Distribution Module to the Evaporator/Blower Module. Then separate the two units. 2. Remove the panel opening foam seal, demister opening foam seal, and heater core tube foam seals from unit. Retaining Clip Removal 3. Remove the retaining clips and screws that hold the upper and lower housings together. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 8466 Case Separation 4. Place the unit in the upside down position. Then separate the two halves of the module. Heater Core Removal 5. Lift the heater core out of the case. Temperature Door Removal 6. Press tab in at base of temperature door and release door from lever. Then remove the door. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 8467 Mode Door Removal 7. Press tab in at base of mode door and release door from lever. Cam Screw Removal 8. Remove Heat/Defrost door cam screw. Cam And Lever Removal 9. Lift the cam and mode door lever off of the housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 8468 Pivot Screw Removal 10. Remove the Heat/Defrost link pivot screw. 11. Lift the Heat/Defrost link and the door as an assembly. Then separate the link from the door. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 8469 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation The instrument panel must be removed in order to remove the Unit Housing. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" . 2. Drain cooling system and remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" 3. Using a refrigerant recovery machine, remove the refrigerant from the A/C system, if equipped. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 4. Remove suction line at expansion valve. Place a piece of tape over open refrigerant line to prevent moisture and/or dirt from entering the line. 5. Remove expansion valve from evaporator. Place a piece of tape over open evaporator fitting to prevent moisture and/or dirt from entering the evaporator. 6. Remove rubber drain tube extension from condensation drain tube. Dash Panel Studs 7. Remove three retaining nuts located in the engine compartment, on the dash panel. Retaining Screws 8. Remove the right side retaining screw. 9. Remove remaining nut located on dash panel stud. 10. Disconnect the blue five way connector from the plenum. Module wiring harness must be removed with module. 11. Remove assembly from the vehicle. For HVAC Unit Housing Disassembly and Assembly, refer to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 8470 INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair The filter/drier is mounted in a rubber grommet on the right side of the engine compartment. The refrigerant must be recovered from the A/C system before replacing the filter/drier assembly. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect liquid line from filter/drier. 2. Disconnect liquid line on suction line assembly from filter/drier. 3. Pull filter/drier out of rubber grommet. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection NO.: 24-13-94 GROUP: Air Conditioning DATE: Sep. 9, 1994 SUBJECT: R-134a Refrigerant Leak Detection MODELS: 1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1994 - 1995 (AB) Ram Van/Ram Wagon 1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1994 - 1995 (AN) Dakota/Dakota Cab & Chassis 1994 (AP) Shadow/Sundance 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1994 (BD) Laser/Talon (Midyear Change) 1994 - 1995 (BR) Ram Truck 1994 - 1995 (B7) Stealth 1994 - 1995 (B8) Colt Vista/Summit Wagon 1994 - 1995 (B9) Colt/Summit 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon 1993 - 1995 (SR) Viper 1994 - 1995 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular structure. Listed below are the R-134a leak detection units currently approved by Chrysler and SAE: HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA Leybold Inficon Models HLD4000 and D/TEC OTC/Yokogawa Model H10N NOTE: LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL, EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM, DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL PROVIDE ACCURATE LEAK DETECTION. TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS SAE Recommended Practice J1628 1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's operating instructions. 2. Leak test with the engine not in operation. 3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may not be measurable since this pressure may not be reached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection > Page 8478 4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No cleaners or solvents shall be used, since many electronic detectors are sensitive to their ingredients. 5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area should be carefully checked with the detector probe, as well as all fittings, hose to line couplings, refrigerant controls, service ports with caps off, brazed or welded areas, and areas around attachment points and holddowns on lines and components. 6. Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. If a leak is found, always continue to test the remainder of the system. 7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50 mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around the position. Slower and closer movement of the probe greatly improves the likelihood of finding a leak. 8. An apparent leak should be verified at least once by blowing shop air into the area of the suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks, blowing out the area with shop air often helps locate the exact position of a leak. 9. Leak testing of the evaporator core while in the air conditioning module should be accomplished by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off, then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting the leak detector probe into the condensate drain hole if no water is present, or into the closest opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent duct. If the detector alarms, a leak apparently has been found. NOTE: R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C MODULE. 9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions included with the detector, or a minimum of 2 minutes. 10. Following any service to the refrigerant system of the vehicle, and any other service which disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant system should be done. NOTE: CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Page 8479 Refrigerant: Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Capacity 1.75 lb (US) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Fluid Specifications Fluid Specifications Ounces Viscosity 4.75 oz (US) ND8 PAG Polyalkaline Glycol Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8483 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8493 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8499 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8503 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8504 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8508 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8509 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8510 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8518 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8519 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8520 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8542 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8543 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 21°C (70°F) and 32°C (90°F) when testing the switch. 1. Disconnect the 3-wire connector from switch lead located behind the glove box. Fig. 2 Fin-sensing Cycling Clutch Switch Harness Connector 16 2. Test for voltage between pin #1 to pin #3 on the wire harness connector. If voltage is detected, jump pin #1 to pin #3 using a jumper wire. Compressor clutch should engage. 3. Check for voltage between pin #1 and pin #2. If no voltage is detected, check fuse and ground circuit. 4. If compressor clutch engages, test for continuity from terminal pin #1 to pin #3 of the switch lead connector. Continuity should be detected. If not, replace the Fin-sensing Cycling Clutch Switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 8544 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: Customer Interest A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > Customer Interest for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8554 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool A/C Pressure Sensor/Switch - Cooling Fan: All Technical Service Bulletins A/C System - Lack of Airflow/Air Not Cool NO: 24-20-94 GROUP: Heating & A/C DATE: Dec. 9, 1994 SUBJECT: Evaporator Freeze Up/Poor A/C Performance MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of a gradual lack of air flow coming out of the panel outlets after the A/C has been in operation, or the air flow is sufficient, but will not cool down. DIAGNOSIS: NOTE: THIS DIAGNOSTIC PROCEDURE REPLACES THE EVAPORATOR PROBE TEST IN THE 1995 NEON SERVICE MANUAL. 1. Move the vehicle into the work area. The area must be between 60~ F and 90~ F. 2. Disconnect the 3-wire connector from the clutch cycling switch lead located behind the glove box. 3. Turn engine on and set A/C to low blower speed, panel, full cool, recirculate. Check for voltage between Pin # 1 and Pin # 2 on the vehicle harness Connector # C403 (See Illustration). If no voltage is detected, check fuse and ground circuit using the wiring diagram. 4. Test for voltage between Pin # 1 and Pin # 3 on connector # C403. If no voltage is detected, then there is no voltage from the Powertrain Control Module. If voltage is detected, jump Pin # 1 to Pin # 3 using a jumper wire. The compressor clutch should engage. If the clutch engages, remove the jumper immediately. If the compressor clutch does not engage, check the operation of the clutch. 5. If the compressor clutch engaged in step 4, connect the 3-wire connector from the clutch cycling switch lead. If the compressor clutch engages (it may remain off for a short time if the compressor clutch was left on for an extended period in step 4 and the evaporator is still cold), proceed to the next step. If it does not engage, proceed to the repair procedure. 6. With the vehicle windows and doors closed, engine idling, and the A/C set to low speed blower, panel, full cool, recirculate, place a thermometer in the center discharge vent and monitor the vent outlet air temperature. 7. If the clutch does not begin to cycle off between 35~ F. and 45~ F., verify that the evaporator probe is fully installed and not loose in the evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, proceed to the repair procedure. NOTE: UNDER HIGH AMBIENT CONDITIONS, IT MAY BE NECESSARY TO RUN THE ENGINE AT 1,500 RPM AND/OR VERIFY THE A/C SYSTEM CHARGE LEVEL TO ACHIEVE THE REQUIRED DISCHARGE AIR TEMPERATURE. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Pressure Sensor/Switch - Cooling Fan: > 242094 > Dec > 94 > A/C System - Lack of Airflow/Air Not Cool > Page 8560 1 4644536 Clutch Cycling Switch REPAIR PROCEDURE: This bulletin involves replacing the clutch cycling switch. 1. Replace the clutch cycling switch with P/N 4644536. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-50-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8564 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8565 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8569 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8570 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8571 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations High Side Service Port The high side service port is located on the filter drier. Low Side Service Port Valve (in Suction Line) The low side service port is located on the suction line. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8575 Service Port HVAC: Service and Repair REMOVAL High Side Service Port Low Side Service Port Valve (in Suction Line) 1. Remove the valve caps. 2. Using a R-134a refrigerant recovery machine, Remove the refrigerant from A/C system. 3. Using a standard valve core tool, remove the valve core. Be careful to prevent any dirt/debris from entering the valve core opening or getting on the replacement valve core. INSTALLATION 1. When assembling the new valve core into the port, the core should be oiled with clean ND8 PAG compressor oil. CAUTION: A valve that is not fully seated can lead to damage to the valve during evacuation and charge. This can result in system refrigerant discharge while uncoupling the charge adapters. 2. Install valve core into port. 3. Evacuate and charge the A/C system. 4. Install the valve caps. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8583 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 8588 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 8589 Airbag Module (Driver) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information Air Bag: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 8592 Air Bag: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 8593 Air Bag: Description and Operation Fig. 1 Driver Airbag WARNING: Never disassemble the driver or passenger airbag module, there are no serviceable parts within the module. DRIVER SIDE The driver airbag module located on the steering wheel is the most visible part of the system. It contains the airbag cushion and its supporting components. The airbag module contains a housing to which the cushion and inflator are attached and sealed. The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cushion. A protective cover is fitted to the front of the driver airbag module and forms a decorative cover in the center of the steering wheel. The driver airbag module is mounted directly to the steering wheel. Fig. 2 Passenger Airbag PASSENGER SIDE The passenger airbag module is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger inflator assembly is contained in the airbag module housing. The airbag module housing is mounted to the instrument panel retainer, knee bolster and glove box. When supplied with the proper electrical signal the inflator produces a gas and discharges it directly into the cushion. A decorative, protective cover is fitted over the airbag module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures Air Bag: Service and Repair Air Bag Module Disposal Procedures After deployment, air bag module should be placed in a plastic bag and disposed of in same manner as any other scrap parts, except that following points should be carefully noted during disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be worn. 2. There may be, adhered to air bag module, material that could irritate eyes and/or skin. Note: If any irritation develops, seek medical attention. a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of irritation continues, consult a physician. 3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4. CAUTION: Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5. Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle interior as follows: a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. 8. An air bag that has been deployed should be removed as described under Airbag Module Replacement. 9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. 10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module, module must be deployed as follows: a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service, air bags must be removed and deployed outside vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8596 Air Bag: Service and Repair Airbag Module Storage & Handling The airbag module must be stored in its original special container until used for service. Additionally, it must be stored: ^ In a clean, dry environment. ^ Away from extreme heat. ^ Away from high voltage energy storage devices like arc welders and transformers. Always place or store the module on a surface with the: ^ The driver airbag trim cover, ^ The passenger airbag clear plastic cover facing up to minimize movement in case of accidental deployment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8597 Air Bag: Service and Repair Driver Side Airbag Module Replacement Fig. 6 Driver Airbag Module WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. WARNING: When vehicle is involved in an impact great enough to deploy the airbag modules, the steering coupler will have to be replaced. WARNING: Replace airbag system components with Chrysler Mopar (R) specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. WARNING: When removing a deployed module, rubber gloves, eye protection and long sleeve shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes. DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Since this powder can irritate the skin, eyes, nose or throat, be sure to wear safety glasses, rubber gloves and long sleeves during cleanup. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. SERVICE OF DEPLOYED AIRBAG MODULE After a DRIVER airbag has been deployed, the airbag module and clockspring assembly must be replaced because they cannot be reused. Other driver airbag system components are replaced if damaged. Fig. 4 Wear Safety Glasses And Gloves CLEAN UP Wear safety glasses, rubber gloves, particle dust mask and protective clothing with long sleeves. Place tape over exhaust vents in air bag so that no additional powder will escape into vehicle. Roll or fold passenger's air bag toward instrument panel surface and close cover over folded air bag. Tape cover closed. Remove driver's air bag module from vehicle then passenger's air bag module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8598 Fig. 5 Vacuum Heater And A/C Outlets Use a vacuum cleaner to remove any residual powder from vehicle interior working from outside to center of vehicle. Be sure to vacuum heater and A/C ducts as well. Run blower motor on low speed and vacuum any powder expelled from plenum. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. REPLACEMENT 1. Disconnect and isolate the battery negative cable. 2. Remove speed control switches or covers from steering wheel back shroud and disconnect the wires. 3. Remove two bolts attaching airbag module from the sides of steering wheel. 4. Lift module and disconnect airbag squib wire connector. 5. Remove driver airbag module. 6. When replacing a deployed driver airbag module, the clockspring must also be replaced. Refer to Clockspring Removal and Installation for proper procedure. 7. For installation, reverse above procedures. a. Connect the squib wire to the module. Make airbag connection by pressing straight in on the connector. The connector should be fully seated feel for positive snap to assure positive connection. b. Install two bolts and tighten to 10 to 11 Nm (90 to 100 in lb) torque. c. Install covers to the steering wheel back shroud or connect the wire connectors to the speed control switches and install switches. Tighten fastener to 2 Nm (20 in lb). d. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8599 Air Bag: Service and Repair Passenger Side Airbag Module Replacement Deployed Module Fig. 7 Remove Or Install Battery Cable WARNING: When removing a deployed module, rubber gloves, eye protection, and a long-sleeved shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes. WARNING: When vehicle is involved in an impact great enough to deploy the airbag modules, the steering coupler will have to be replaced. WARNING: Replace airbag system components with Chrysler Mopar (R) specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Since this powder can irritate the skin, eyes, nose or throat, be sure to wear safety glasses, rubber gloves and long sleeves during cleanup. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. SERVICE OF DEPLOYED AIRBAG MODULE After a PASSENGER airbag has been deployed, the passenger airbag module must be replaced because it cannot be reused. Other components are replaced if damaged. These might include the trim bezel, top cover or the entire instrument panel. Fig. 4 Wear Safety Glasses And Gloves CLEAN UP Wear safety glasses, rubber gloves, particle dust mask and protective clothing with long sleeves. Place tape over exhaust vents in air bag so that no additional powder will escape into vehicle. Roll or fold passenger's air bag toward instrument panel surface and close cover over folded air bag. Tape cover closed. Remove driver's air bag module from vehicle then passenger's air bag module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8600 Fig. 5 Vacuum Heater And A/C Outlets Use a vacuum cleaner to remove any residual powder from vehicle interior working from outside to center of vehicle. Be sure to vacuum heater and A/C ducts as well. Run blower motor on low speed and vacuum any powder expelled from plenum. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. REPLACEMENT 1. Disconnect and isolate the battery negative cable. 2. Roll/fold airbag towards instrument panel. 3. Close door over folded airbag and tape door closed. Fig. 8 Instrument Panel 4. Remove instrument panel top cover. 5. Remove instrument panel right trim panel. 6. Open glove box and push the sides inward allowing the door bumper to pass and box to open. Fig. 9 Passenger Airbag Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8601 7. Remove the four trim screws which attach the module to the top instrument panel. 8. Remove two module attaching nuts from the support structure. 9. Lift module up until the electrical connector is visible and disconnect the connector from module. 10. For installation, reverse above procedures. - Tighten trim screws to 2 Nm (20 in lb) torque. - Tighten the module nuts to 22 to 34 Nm (200 to 300 in lb) torque. Undeployed Module Fig. 7 Remove Or Install Battery Cable NOTE: Use this procedure when removing a module for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Fig. 8 Instrument Panel 2. Remove instrument panel top cover. 3. Remove instrument panel right trim bezel. 4. Open glove box and push the sides inward allowing the door bumper to pass and box to open. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 8602 Fig. 9 Passenger Airbag Module 5. Remove the four trim screws which attach the passenger airbag module to the top instrument panel. 6. Remove two module attaching nuts from the support structure. 7. Lift module up until the electrical connector is visible and disconnect the connector from module. 8. For installation, reverse above procedures. - Tighten trim screws to 2 Nm (20 in lb) torque. - Tighten the module nuts to 22 to 34 Nm (200 to 300 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations > Page 8606 Air Bag Control Module Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 8609 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 8610 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8611 Supplemental Restraint System (SRS) Control Module: Description and Operation Fig. 3 Passenger Airbag OPERATION The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM will store sufficient energy to deploy the airbags for at least one second after the battery is disconnected. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for six to eight seconds every time the vehicle is started. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage - to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the fuse block bus bar that feeds the F15 circuit. A 30 amp maxi fuse in the PDC protects the Al and A21 circuits. A 10 amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 30 amp maxi fuse in the PDC protects the A2 and A22 circuits. A 10 amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8612 Supplemental Restraint System (SRS) Control Module: Testing and Inspection - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8613 Supplemental Restraint System (SRS) Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Automatic transaxle only, remove shifter knob fastener and remove shifter knob. 3. Remove attaching screw from each of the two forward cup holders of the floor console. Remove screws at the rear of the console or with armrest inside of console bin. 4. Pull park brake lever all the way up. Fig. 12 Airbag Control Module 5. Lift the floor console at the rear and guide it out from under the instrument panel. 6. Remove module mounting nuts and remove module. Fig. 13 Airbag Control Module 7. Disconnect ACM 4-way and 13-way connectors. INSTALLATION 1. Connect ACM both connectors and ensure both connectors and all locking tabs are engaged. CAUTION: Use supplied screws only. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8614 3. Install floor console into position. 4. Install attaching screw in each of the two forward cup holders. 5. Install screws at the rear of the console or with armrest inside of console shifter bezel with screw located in ash receiver. 6. Replace shifter knob and fastener. 7. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8619 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8620 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8621 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8622 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8623 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8624 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8625 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8626 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8627 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8628 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8629 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8630 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8631 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clock Spring: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 8636 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Component Locations Clockspring Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Component Locations > Page 8639 Clockspring Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Customer Safety Information Clock Spring: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Customer Safety Information > Page 8642 Clock Spring: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8643 Clock Spring: Description and Operation PURPOSE The clockspring, mounted on the steering wheel column, behind the steering wheel, is used to maintain a continuous electrical circuit between the wiring harness and the: Driver's airbag module. - Speed control switches. - Horn switches. CONSTRUCTION The clockspring assembly consists of a flat, ribbon like, electrically conductive tape, which winds and unwinds as the steering wheel is rotated. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8644 Clock Spring: Adjustments CLOCKSPRING CENTERING PROCEDURE If the rotating tape within the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail during use. The following procedure MUST BE USED to center the clockspring if: The clockspring is not known to be properly positioned - The front wheels were moved - The steering wheel was moved from the half turn (180 degrees) to the right (clockwise) position. WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Remove clockspring, refer to Clockspring Removal. 2. Rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of travel. Do not apply excessive torque. 3. From the end of travel, rotate the rotor two full turns and a half in the counterclockwise direction. The horn wire and the squib wire should end up at the bottom. If not, rotate the rotor counter clockwise until the wires are properly orientated, but not more than half turn (180 degrees). Engage clockspring locking mechanism. 4. For installation, refer to Clockspring Assembly/Spiral Cable/Service and Repair. 5. Do not connect battery negative cable. Refer to Testing and Inspection/Procedures for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clock Spring <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8645 Clock Spring: Service and Repair REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Place the front road wheels in the straight ahead position then: - Rotate the steering wheel half turn (180 degrees) to the right (clockwise) - Lock column with ignition lock cylinder. 2. Disconnect and isolate the battery negative cable. 3. Wait two minutes for the reserve capacitor to discharge before removing non-deployed module. 4. Remove speed control switch mounting screws, switches and disconnect the wire connectors or remove covers. 5. Remove the Driver Airbag Module attaching bolts from under the speed control switches or covers. 6. Lift module and disconnect the airbag and horn wire connectors. 7. Remove the steering wheel. 8. Remove upper and lower steering column shrouds to gain access to clockspring wiring. 9. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness at the base of the clockspring. 10. Unlatch and remove clockspring assembly from steering shaft. The clockspring cannot be repaired, and must be replaced if faulty 11. Rotate clockspring rotor a half turn (180 degrees) to the left (counter clockwise). 12. Lock the clockspring rotor in the center position as follows: Insert a paper clip wire through the hole in the rotor at the 10 O'clock position and bend to prevent it from falling out. INSTALLATION 1. Confirm that: - The steering wheel position is a half turn (180 degrees) to the right (clockwise) - The column is locked with the ignition cylinder lock. - Check that the turn signal stalk is in the neutral position - When reusing the clockspring, remove locking wire and rotate clockspring rotor one half turn (180 degrees) to the right (clockwise). Locate the clockspring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering column. - When installing a new clockspring, position the front wheels straight a head. Remove grenade pin. Rotate clockspring rotor one half turn (180 degrees) to the right (clockwise). 2. Connect the clockspring to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged and the halo lamp wire is in position. 3. Install steering column shrouds. Be sure all wires are inside of shrouds. 4. Install steering wheel ensuring the flats on hub align with the clockspring. Pull the horn, airbag and speed control leads through the larger slot. Ensure leads do not get pinched under the steering wheel. 5. Route speed control wires under and behind the airbag module mounting tabs. 6. Connect the horn lead wire and the airbag lead wire to the airbag module. 7. Install the airbag module and tighten bolts to 12 to 14 Nm (105 to 125 in lb) torque. 8. Connect the speed control wires to the switches and install switches. Tighten screws to 2 Nm. (20 in lb) torque. 9. Do not connect the battery negative cable. Refer to Airbag System Arming procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations Data Link Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 8653 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 8656 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation AIRBAG IMPACT SENSORS Two airbag impact sensors provide input to the Air-bag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connector. Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 8659 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Page 8660 Impact Sensor: Testing and Inspection Helpful Information - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8663 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8664 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8665 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Locations Air Bag Warning Lamp: Locations The warning lamp is located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Locations > Page 8669 Air Bag Warning Lamp: Description and Operation AIRBAG WARNING LAMP The Airbag Warning lamp is used to alert the operator of a problem with the airbag system. The lamp is illuminated when the Airbag Control Module (ACM) grounds the R41 circuit. Refer to the appropriate section of the Service Manual or the Diagnostic Test Procedures Manual to diagnose this system. Circuit R41 connects the airbag warning lamp to cavity 7 of the ACM 13-way connector. The airbag warning lamp is part of the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Locations > Page 8670 Air Bag Warning Lamp: Testing and Inspection - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8675 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8676 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8677 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8678 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8679 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations > Page 8684 Air Bag Control Module Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 8687 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 8688 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8689 Supplemental Restraint System (SRS) Control Module: Description and Operation Fig. 3 Passenger Airbag OPERATION The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM will store sufficient energy to deploy the airbags for at least one second after the battery is disconnected. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for six to eight seconds every time the vehicle is started. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage - to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the fuse block bus bar that feeds the F15 circuit. A 30 amp maxi fuse in the PDC protects the Al and A21 circuits. A 10 amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 30 amp maxi fuse in the PDC protects the A2 and A22 circuits. A 10 amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8690 Supplemental Restraint System (SRS) Control Module: Testing and Inspection - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8691 Supplemental Restraint System (SRS) Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Automatic transaxle only, remove shifter knob fastener and remove shifter knob. 3. Remove attaching screw from each of the two forward cup holders of the floor console. Remove screws at the rear of the console or with armrest inside of console bin. 4. Pull park brake lever all the way up. Fig. 12 Airbag Control Module 5. Lift the floor console at the rear and guide it out from under the instrument panel. 6. Remove module mounting nuts and remove module. Fig. 13 Airbag Control Module 7. Disconnect ACM 4-way and 13-way connectors. INSTALLATION 1. Connect ACM both connectors and ensure both connectors and all locking tabs are engaged. CAUTION: Use supplied screws only. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 8692 3. Install floor console into position. 4. Install attaching screw in each of the two forward cup holders. 5. Install screws at the rear of the console or with armrest inside of console shifter bezel with screw located in ash receiver. 6. Replace shifter knob and fastener. 7. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8699 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8705 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8706 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8707 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8708 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8709 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8710 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8711 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8712 detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8713 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8714 POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8715 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8716 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8717 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8718 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8719 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8720 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 8721 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 8726 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 8727 Seat Belt: Service and Repair FRONT OUTBOARD SEAT BELT Removal 1. Slide lower seat belt anchor cover upward to expose bolt. Front Outboard Seat Belt Anchor 2. Remove bolt holding lower anchor bolt to floor below door sill. 3. Separate lower anchor from floor. 4. Remove rear seat cushion and back. 5. Remove quarter trim panel. 6. Guide seat belt webbing through slot in quarter trim panel. 7. Disengage wire connector from seat belt retractor. Front Outboard Seat Belt Retractor 8. Remove bolts holding seat belt retractor to B-pillar. 9. Separate seat belt retractor from vehicle. Installation Reverse the preceding operation. Tighten seat belt anchor bolt to 39 Nm (29 ft. lbs.). FRONT SEAT BELT BUCKLE 1. Move front seat to the forward position. 2. Remove bolt holding seat belt buckle to seat. 3. Separate seat belt buckle from scat. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 8728 FRONT SEAT BELT RETRACTOR 1. Remove B-pillar trim. 2. Remove bolt holding seat belt retractor to B-pillar. 3. Separate seat belt retractor from vehicle. 4. Reverse the preceding operation for installation. REAR SEAT BELT BUCKLE 1. Remove rear seat cushion. 2. Remove rear seat back. 3. Separate rear seat belt buckle from vehicle. 4. Reverse the preceding operation for installation. REAR SEAT BELT RETRACTOR 1. Remove rear seat cushion and back. 2. Remove seat belt bezel from parcel shelf cover. 3. Remove rear seat closure panel silencer pad as necessary to gain access to retractor. 4. Remove bolt holding seat belt lower anchor to floor. Rear Seat Belt Retractor 5. Remove bolt holding retractor to rear seat closure panel. 6. Push seat belt bezel and buckle stab through access hole in parcel shelf. 7. From in luggage compartment, separate rear seat belt retractor from vehicle. 8. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Seat Belt Buckle - Replacement Seat Belt Buckle: Technical Service Bulletins Seat Belt Buckle - Replacement NO: 23-66-95 GROUP: Body DATE: Nov. 3, 1995 SUBJECT: Seat Belt Buckle Replacement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-81-94 REV. A DATED NOV. 4, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon DISCUSSION: Seat belt buckle assemblies, which are different in appearance, have been released for the above listed vehicles. Therefore, if any one of the front or rear seat belt buckles require replacement, all four seat belt buckles are to be replaced. ** PARTS REQUIRED: ** AR 4864882 Quartz, Seat Belt Buckle Package (Front & Rear), Four Door, Built Prior to 8/8/95. AR 4864883 Driftwood, Seat Belt Buckle Package (Front & Rear), Four Door, Built Prior to 8/8/95. AR 4864885 Agate, Seat Belt Buckle Package (Front & Rear), Two & Four Door, Built On or After 8/8/95. AR 4864887 Driftwood, Seat Belt Buckle Package (Front & Rear), Two & Four Door, Built On or After 818195. REPAIR PROCEDURE: This bulletin involves replacing all seat belt buckles with revised Parts listed above. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-13-01-93 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair Front Shoulder Belt Adjuster FRONT SHOULDER BELT ADJUSTER 1. Remove B-pillar trim. 2. Remove bolt holding shoulder belt adjuster to B-pillar. 3. Separate shoulder belt adjuster from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING INDICATOR The Fasten Seat Belt indicator is used with the warning chime to tell the operator to fasten the seat belt. The seat belt switch is located in the driver's side B-pillar that is normally open when the seat belt is buckled. If the seat belt is not buckled, the switch closes, and a ground path is completed from the G1O circuit to the Z1 circuit. This illuminates the lamp in the instrument cluster. Ground for the seat belt switch is terminated at the right rear wheel house. When the ignition switch is moved to the START position, the lamp illuminates. Logic internal to the instrument cluster determines the length of time the lamp remains illuminated. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8744 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8745 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8746 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8747 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8748 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8749 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8750 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8751 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8752 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8753 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8754 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8755 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 8756 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 8761 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 8764 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation AIRBAG IMPACT SENSORS Two airbag impact sensors provide input to the Air-bag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connector. Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 8767 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Page 8768 Impact Sensor: Testing and Inspection Helpful Information - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse-protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8771 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8772 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 8773 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8779 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8780 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8781 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8786 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8787 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 8788 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation SPEEDOMETER / ODOMETER The speedometer and odometer receive their information on the G7 circuit from the vehicle-speed sensor. This circuit also provides a signal to the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8792 Driver/Vehicle Information Display: Service and Repair 1. Disconnect battery ground cable. 2. Remove instrument panel top cover and cluster bezel. 3. Remove four screws attaching cluster housing to base panel. 4. Pull cluster rearward to disconnect from base panel. 5. Remove cluster assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo: > 087094 > Dec > 94 > Radio Poor AM Reception/Static Radio/Stereo: Customer Interest Radio - Poor AM Reception/Static NO: 08-70-94 GROUP: Electrical DATE: Dec. 9, 1994 SUBJECT: Poor AM Radio Reception/Static MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of poor AM radio reception/static. PARTS REQUIRED: AR 4661838 Ground Strap (Engine To Fender) AR 4661932 Ground Strap (Hood Hinge To Body) AR 4469334 Ground Strap (Engine Mount) AR 5269216 Antenna Lead To Radio AR 4798290 Antenna Base & Bracket Assembly Package REPAIR PROCEDURE: This bulletin involves performing a diagnostic procedure to determine the cause of poor AM radio reception by examining body/engine grounds, antenna installation/connections, speaker connections/operation and radio connections. NOTE: POOR AM RECEPTION/STATIC WILL AFFECT ALL SPEAKERS EQUALLY WITH THE SYSTEM EQUALLY BALANCED FRONT TO REAR AND SIDE TO SIDE. AUDIO DIAGNOSTICS WILL NOT BE COVERED IN THIS BULLETIN. 1. Open the hood and secure with hood prop rod. 2. Verify that the engine to fender ground strap is secure. Install P/N 4661838 ground strap if it is damaged or missing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo: > 087094 > Dec > 94 > Radio Poor AM Reception/Static > Page 8806 3. Inspect the hood hinge assemblies and verify that each hood hinge has a ground strap between the hood hinge and body. Install P/N 4661932 ground strap if one is damaged or missing. 4. Unlatch the two clips holding the Power Distribution Center to the battery thermoguard and lift it out of the way. Verify that the engine mount ground strap is secure. Install P/N 4469334 ground strap if damaged or missing. 5. With the hood closed, inspect the antenna mast to see that it is secured to the antenna assembly post. If the mast is loose, remove the mast and apply Mopar Lock N' Seal Adhesive, P/N 4318031, to the threads. Install the mast into the antenna assembly post until the mast bottoms on antenna assembly post. 6. Turn the ignition switch to the ON position, but do not start. Do not use the accessory position. 7. Tune the radio to a weak AM station. Pull the antenna mast rearward approximately 30 Degrees and let it whip back an forth and then pull the mast sideways approximately 30 Degrees and let it whip back an forth. If loud static or "popping" sound is heard through the radio speakers, remove the right fender shield and check the antenna bracket mounting screw for proper tightness. If the screw is tight, the antenna base and bracket will have to be replaced, which is covered in Step 9. 8. Remove the right side cowl trim panel and confirm that the antenna cable connector between the antenna lead and radio-to-antenna lead in wire is secure. If static or "popping" sound when the cable leads are wiggled, determine which cable is at fault. If it is the extension cable, replace it with P/N 5269216. If the noise is due to the antenna lead in wire. the antenna base and bracket will have to be replaced. Proceed to the next step. 9. If it was determined in Step 7 or 8 that the antenna base and bracket requires replacement, replace the assembly with P/N 4798290. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo: > 087094 > Dec > 94 > Radio Poor AM Reception/Static > Page 8807 DO NOT USE PUSH PINS IN THE BOTTOM TWO HOLES THAT RETAIN THE INNER FENDER SHIELD TO THE FENDER. USE THE TWO SCREWS AND U-NUTS PROVIDED IN THE ANTENNA BASE AND BRACKET PACKAGE. 10. If static or "popping" noise was not heard in the preceding diagnostic procedure, and AM reception is still poor, remove the radio, to examine the rear electrical connections. 11. Confirm the following connections at the rear of the radio. A) The antenna cable is securely fastened to the radio and the connection is functional. Repair or replace radio-to-antenna lead, P/N 5269216. B) The radio ground terminal is secure to the radio and the ground circuit to the terminal is functional and the terminal is not spread. Repair as necessary. C) Confirm that the two 7-way (C209-black and C210-gray) connectors are functional and that the terminals are not pushed out or spread. Repair as necessary. If items A through C check out okay, remove the radio and exchange it through the Mopar Authorized Service Centers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo: > 087094 > Dec > 94 > Radio - Poor AM Reception/Static Radio/Stereo: All Technical Service Bulletins Radio - Poor AM Reception/Static NO: 08-70-94 GROUP: Electrical DATE: Dec. 9, 1994 SUBJECT: Poor AM Radio Reception/Static MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Customer complaint of poor AM radio reception/static. PARTS REQUIRED: AR 4661838 Ground Strap (Engine To Fender) AR 4661932 Ground Strap (Hood Hinge To Body) AR 4469334 Ground Strap (Engine Mount) AR 5269216 Antenna Lead To Radio AR 4798290 Antenna Base & Bracket Assembly Package REPAIR PROCEDURE: This bulletin involves performing a diagnostic procedure to determine the cause of poor AM radio reception by examining body/engine grounds, antenna installation/connections, speaker connections/operation and radio connections. NOTE: POOR AM RECEPTION/STATIC WILL AFFECT ALL SPEAKERS EQUALLY WITH THE SYSTEM EQUALLY BALANCED FRONT TO REAR AND SIDE TO SIDE. AUDIO DIAGNOSTICS WILL NOT BE COVERED IN THIS BULLETIN. 1. Open the hood and secure with hood prop rod. 2. Verify that the engine to fender ground strap is secure. Install P/N 4661838 ground strap if it is damaged or missing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo: > 087094 > Dec > 94 > Radio - Poor AM Reception/Static > Page 8813 3. Inspect the hood hinge assemblies and verify that each hood hinge has a ground strap between the hood hinge and body. Install P/N 4661932 ground strap if one is damaged or missing. 4. Unlatch the two clips holding the Power Distribution Center to the battery thermoguard and lift it out of the way. Verify that the engine mount ground strap is secure. Install P/N 4469334 ground strap if damaged or missing. 5. With the hood closed, inspect the antenna mast to see that it is secured to the antenna assembly post. If the mast is loose, remove the mast and apply Mopar Lock N' Seal Adhesive, P/N 4318031, to the threads. Install the mast into the antenna assembly post until the mast bottoms on antenna assembly post. 6. Turn the ignition switch to the ON position, but do not start. Do not use the accessory position. 7. Tune the radio to a weak AM station. Pull the antenna mast rearward approximately 30 Degrees and let it whip back an forth and then pull the mast sideways approximately 30 Degrees and let it whip back an forth. If loud static or "popping" sound is heard through the radio speakers, remove the right fender shield and check the antenna bracket mounting screw for proper tightness. If the screw is tight, the antenna base and bracket will have to be replaced, which is covered in Step 9. 8. Remove the right side cowl trim panel and confirm that the antenna cable connector between the antenna lead and radio-to-antenna lead in wire is secure. If static or "popping" sound when the cable leads are wiggled, determine which cable is at fault. If it is the extension cable, replace it with P/N 5269216. If the noise is due to the antenna lead in wire. the antenna base and bracket will have to be replaced. Proceed to the next step. 9. If it was determined in Step 7 or 8 that the antenna base and bracket requires replacement, replace the assembly with P/N 4798290. NOTE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo: > 087094 > Dec > 94 > Radio - Poor AM Reception/Static > Page 8814 DO NOT USE PUSH PINS IN THE BOTTOM TWO HOLES THAT RETAIN THE INNER FENDER SHIELD TO THE FENDER. USE THE TWO SCREWS AND U-NUTS PROVIDED IN THE ANTENNA BASE AND BRACKET PACKAGE. 10. If static or "popping" noise was not heard in the preceding diagnostic procedure, and AM reception is still poor, remove the radio, to examine the rear electrical connections. 11. Confirm the following connections at the rear of the radio. A) The antenna cable is securely fastened to the radio and the connection is functional. Repair or replace radio-to-antenna lead, P/N 5269216. B) The radio ground terminal is secure to the radio and the ground circuit to the terminal is functional and the terminal is not spread. Repair as necessary. C) Confirm that the two 7-way (C209-black and C210-gray) connectors are functional and that the terminals are not pushed out or spread. Repair as necessary. If items A through C check out okay, remove the radio and exchange it through the Mopar Authorized Service Centers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8817 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8818 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8819 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8820 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8821 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8822 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8823 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8824 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8825 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8826 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8827 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8828 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8829 Radio/Stereo: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8830 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8831 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8832 Radio/Stereo: Electrical Diagrams Radio System (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 8833 Radio System (Part 2 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation Radio/Stereo: Description and Operation Radio Operation RADIO OPERATION When the ignition switch is in either the ACCESSORY or RUN position, if connects circuit A1 from the Power Distribution Center (PDC) to circuit A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds two circuits, one of which is circuit X12. Circuit X12 powers the radio. A 10 amp fuse, in cavity 16 of the fuse block, protects circuit X12. Circuit Z9 supplies the ground path for the radio. The grounding point for circuit Z9 is the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation > Page 8836 Radio/Stereo: Description and Operation Radio Memory RADIO MEMORY Circuit M1 from the Power Distribution Center (PDC) supplies power for the radio memory. The circuit contains the Ignition Off Draw (IOD) fuse. The IOD fuse is removed during vehicle shipping to prevent excessive battery draw. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation > Page 8837 Radio/Stereo: Description and Operation Radio Illumination RADIO ILLUMINATION When the parking lamps or headlamps are ON, circuits E2 and L7 power the radio illumination lamps and park lamps. Circuit E2 feeds the illumination lamp. Circuit L7 feeds the park lamps of the radio. Circuit F33 feeds circuit L7. A 4 amp fuse, in cavity 12 of the fuse block, protects circuit E2. A 15 amp fuse, in cavity 2 of the fuse block, protects circuits L7 and F33. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Page 8838 Radio/Stereo: Testing and Inspection ^ Circuit M1 also powers the vanity lamps, glove box lamp, time delay relay, dome lamps, underhood lamp, cargo lamp, and power mirrors. ^ If the radio does not operate, check for blown fuses in circuits A1 and X12. ^ Circuits A3, and F33 feed the L7 circuit. ^ If the radio illumination lamps do not operate, check for blown fuses in circuits E2, F33, and A3. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Page 8839 Radio/Stereo: Service and Repair 1. Disconnect battery ground cable. 2. Remove center module bezel. 3. Remove two mounting screws on radio to remove from instrument panel. 4. Disconnect wiring and antenna lead from radio. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation SPEAKERS Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the speaker in the right front door. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the left rear speaker. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest for Front Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Front Bumper Cover / Fascia: Customer Interest Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest for Front Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 8854 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Front Bumper Cover / Fascia: All Technical Service Bulletins Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 8860 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > Page 8861 Front Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > Page 8862 Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > Page 8863 PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Rear Bumper Cover / Fascia: Customer Interest Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 8873 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Rear Bumper Cover / Fascia: All Technical Service Bulletins Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 8879 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > 051694A > Jan > 95 > Front Brakes - Moaning Noises Brake Disc: All Technical Service Bulletins Front Brakes - Moaning Noises NO: 05-16-94 Rev. A GROUP: Brakes DATE: Jan. 13, 1995 SUBJECT: Moaning Noise from Front Brakes THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-16-94 DATED SEP. 9, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PROCEDURE HAS BEEN CHANGED TO REPLACE RATHER THAN REFACE FRONT DISC BRAKE ROTORS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 1/3/95 (MDH O1-03-XX) EQUIPPED WITH FOUR (4) STUD HUBS, SALES CODES BRC AND BRH.** SYMPTOM/CONDITION: A low frequency moan, growl or a grinding noise that can be heard when stopping during moderate to heavy braking. The sound varies with vehicle speed and usually occurs when braking above 45 MPH. DIAGNOSIS: With the windows closed, radio and the heater/AC system off, road test the vehicle on a smooth road surface and apply the brakes heavily from a speed above 45 MPH. Avoid skidding the tires. if the noise is heard, proceed with the following repair. **PARTS REQUIRED: 2 4509715 Disk Brake Rotor** REPAIR PROCEDURE: **This bulletin involves replacing the front disc brake rotors with a revised part.** 1. Remove the disc brake rotors as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 5-45. 2. Install the disc brake rotors as outlined in the Service Manual, Page 546. NOTE: REPLACEMENT OF DISC BRAKE PADS IS NOT REQUIRED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Disc Brake Rotor. Replace. Left Side Labor Operation No: 05-21-10-91.......................................................................................................................................... ................................0.3 Hrs. Disc Brake Rotor. Replace. Right Side 05-21-10-92............................................................................ ..............................................................................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 8885 Rear Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 8886 Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 8887 PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise Cowl: Customer Interest A/C, Heater - Debris From Vents/Noise NO: 24-02-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Leaves/Debris in Heater-A/C System MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: ^ Debris comes out of the air outlets (applies to heater only equipped vehicles). ^ Noise at heater-A/C blower motor wheel due to leaves/debris in wheel. PARTS REQUIRED: 1 NPN Hardware Cloth (3" x 24" x 1/4"), Zinc Plated or Corrosion Resistant Coating) 3 6032723 Screws AR 4467708 Mopar Silicone Glass Sealer AR 4655021 Windshield Cowl Screen (for vehicles built prior to Jun. 6, 1994, MDH 06-06-XX). REPAIR PROCEDURE: This bulletin involves installing a fabricated screen over the cowl plenum air inlet openings on all vehicles, and on some vehicles cleaning air outlets and/or installing a revised windshield cowl screen. 1. For vehicles equipped with A/C, proceed to step 5. For heater only equipped vehicles, remove all upper panel air outlets by pivoting them downward with adequate force. Remove any debris/leaves from the outlet louvers. 2. Check the defroster outlet for any debris. If debris is evident, remove the instrument panel top cover as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page SE-7 and remove the debris. 3. Check the heater duct openings and remove any debris. With all outlets removed, turn blower to high and move the temperature control back and forth from cold to hot while cycling through all air distribution modes to blow out any debris in the duct system. 4. Install the instrument panel top cover, if removed. Install the air outlets. The outlets can only be installed one way, with the large diameter hinge on the left side. If noise was heard from the blower motor wheel, proceed to the next step, otherwise go to step 8. 5. Remove the blower motor and wheel assembly as outlined in the Service Manual, Pages 24-11 through 24-12. Remove any debris/leaves from the blower wheel and in the heater-A/C housing. 6. Remove any debris from the A/C condensate drain tube. 7. Install the blower motor and wheel assembly back into the heater-A/C housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 8896 8. Cut a section of hardware cloth as indicated (Figure 1). Cut the wire harness opening in an "X" pattern and fold inward (Figure 2). 9. Remove the wiper arm/blade assemblies. 10. Open the hood and remove the rear hood seal and windshield cowl screen. 11. Remove the blower motor resistor block, with wiring attached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 8897 12. Align the pre-cut hardware cloth over the air inlet openings (Figure 3). 13. Carefully slide the wiring harness up through the slit in the hardware cloth to the pre-cut opening. 14. Install the resistor block over the screen. Make sure the screen does not come in contact with the elements in the resistor block (Figure 2). 15. Install three screws, P/N 6032723, to secure the screen to the cowl plenum. 16. Apply Mopar Silicone Glass Sealer, P/N 4467708, around the outside edge of the screen to eliminate any potential for buzz, squeaks or rattles. NOTE: VEHICLES BUILT PRIOR TO JUN. 6, 1994 (MDH 06-06-XX) REQUIRE A NEW WINDSHIELD COWL SCREEN, P/N 4655021. 17. Install the windshield cowl screen and hood seal. 18. Install windshield wiper arm/blade assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Screen Cowl Install. Remove Debris from Heater Housing. A/C Equipped Vehicles 23-43-68-90...... .............................................................................................................................................................. ......0.4 Hrs. Screen Cowl Install. Remove Debris From Outlets and Heater Housing. Heater Only Equipped Vehicles 23-43-68-91........................................................................................................................... ...............................................0.6 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor Cowl: Customer Interest A Pillar - Water Leaks To Interior Floor NO: 23-48-94 GROUP: Body EFFECTIVE DATE: Jul. 15, 1994 SUBJECT: Water Leak In Passenger Compartment Under Instrument Panel MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Water leak from under instrument panel onto front floor area. Water may also be noticed in the glove box. Sloshing noise may be heard from instrument panel on turns. Water may leak on passenger floor area on left hand turn. DIAGNOSIS: 1. Remove instrument panel top cover and cluster bezel assembly by lifting up on the bottom outer areas of the cluster bezel and along the rearward edge to disengage the clips. Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel. 2. Remove both right and left A-Pillar trim moldings by pulling outward on the molding to disengage clips. 3. Run water on the windshield starting at the bottom and working up around the sides and around the top of the glass. Inspect for water dripping or running down the A-Pillars or front part of the windshield through the urethane bead. If a windshield water leak is found, repair as necessary before proceeding to the repair procedure. PARTS REQUIRED: AR 4318088 Butyl Rubber Sealer (Or Equivalent) AR 4467708 Silicone Windshield & Glass Sealer (Or Equivalent) AR 4655021 Cowl Screen Assembly (With Lip Seal) AR 4783100 Cowl Drain Tube AR 4655604 Cowl Top Patch REPAIR PROCEDURE: This bulletin involves sealing the cowl plenum, installing a cowl screen, and a cowl plenum drain tube. 1. On the inside of the vehicle, on the left top corner of the dash, fold back the cowl top silencer pad and temporarily retain it under the VIN plate pad on the instrument panel. Fold back the cowl top patch to gain access to the dash panel access hole. Refer to Figures 1 and 2. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8902 2. Look through the access hole in the cowl top and inspect for any water remaining in the cowl plenum. Remove any water that is present by using a vacuum through the access hole. Refer to Figure 1. 3. Remove the wiper arm assemblies. 4. Open the hood and remove the cowl-to-hood seal and the cowl screen assembly. 5. Disconnect the Wiper motor electrical connector and the three bolts holding the wiper assembly then remove the wiper motor assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8903 6. Apply Butyl Rubber Sealer P/N 4318088 (Or Equivalent) to the following areas of the cowl plenum. Refer to Figure 2, 3 and 4. A. Horizontal & vertical seams in the cowl plenum. B. Upper corner of the cowl plenum to cowl top extension (Right and Left sides). C. Bottom corner of A-Pillar transition (Right and Left sides). D. Horizontal and vertical seams under hood hinge attachment area (Right and Left sides.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8904 7. Force Silicone Windshield & Glass Sealer, P/N 4467708 (Or Equivalent), beneath the windshield edge to seal possible sheet metal leak covered by glass. Refer to Figure 4. 8. Install the wiper motor assembly. 9. Install a new Cowl Screen Assembly, P/N 4655021. 10. Install the wiper arm assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8905 11. Ensure drain tube is properly installed (Fig 5). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise Cowl: All Technical Service Bulletins A/C, Heater - Debris From Vents/Noise NO: 24-02-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Leaves/Debris in Heater-A/C System MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: ^ Debris comes out of the air outlets (applies to heater only equipped vehicles). ^ Noise at heater-A/C blower motor wheel due to leaves/debris in wheel. PARTS REQUIRED: 1 NPN Hardware Cloth (3" x 24" x 1/4"), Zinc Plated or Corrosion Resistant Coating) 3 6032723 Screws AR 4467708 Mopar Silicone Glass Sealer AR 4655021 Windshield Cowl Screen (for vehicles built prior to Jun. 6, 1994, MDH 06-06-XX). REPAIR PROCEDURE: This bulletin involves installing a fabricated screen over the cowl plenum air inlet openings on all vehicles, and on some vehicles cleaning air outlets and/or installing a revised windshield cowl screen. 1. For vehicles equipped with A/C, proceed to step 5. For heater only equipped vehicles, remove all upper panel air outlets by pivoting them downward with adequate force. Remove any debris/leaves from the outlet louvers. 2. Check the defroster outlet for any debris. If debris is evident, remove the instrument panel top cover as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page SE-7 and remove the debris. 3. Check the heater duct openings and remove any debris. With all outlets removed, turn blower to high and move the temperature control back and forth from cold to hot while cycling through all air distribution modes to blow out any debris in the duct system. 4. Install the instrument panel top cover, if removed. Install the air outlets. The outlets can only be installed one way, with the large diameter hinge on the left side. If noise was heard from the blower motor wheel, proceed to the next step, otherwise go to step 8. 5. Remove the blower motor and wheel assembly as outlined in the Service Manual, Pages 24-11 through 24-12. Remove any debris/leaves from the blower wheel and in the heater-A/C housing. 6. Remove any debris from the A/C condensate drain tube. 7. Install the blower motor and wheel assembly back into the heater-A/C housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 8911 8. Cut a section of hardware cloth as indicated (Figure 1). Cut the wire harness opening in an "X" pattern and fold inward (Figure 2). 9. Remove the wiper arm/blade assemblies. 10. Open the hood and remove the rear hood seal and windshield cowl screen. 11. Remove the blower motor resistor block, with wiring attached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 8912 12. Align the pre-cut hardware cloth over the air inlet openings (Figure 3). 13. Carefully slide the wiring harness up through the slit in the hardware cloth to the pre-cut opening. 14. Install the resistor block over the screen. Make sure the screen does not come in contact with the elements in the resistor block (Figure 2). 15. Install three screws, P/N 6032723, to secure the screen to the cowl plenum. 16. Apply Mopar Silicone Glass Sealer, P/N 4467708, around the outside edge of the screen to eliminate any potential for buzz, squeaks or rattles. NOTE: VEHICLES BUILT PRIOR TO JUN. 6, 1994 (MDH 06-06-XX) REQUIRE A NEW WINDSHIELD COWL SCREEN, P/N 4655021. 17. Install the windshield cowl screen and hood seal. 18. Install windshield wiper arm/blade assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Screen Cowl Install. Remove Debris from Heater Housing. A/C Equipped Vehicles 23-43-68-90...... .............................................................................................................................................................. ......0.4 Hrs. Screen Cowl Install. Remove Debris From Outlets and Heater Housing. Heater Only Equipped Vehicles 23-43-68-91........................................................................................................................... ...............................................0.6 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor Cowl: All Technical Service Bulletins A Pillar - Water Leaks To Interior Floor NO: 23-48-94 GROUP: Body EFFECTIVE DATE: Jul. 15, 1994 SUBJECT: Water Leak In Passenger Compartment Under Instrument Panel MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Water leak from under instrument panel onto front floor area. Water may also be noticed in the glove box. Sloshing noise may be heard from instrument panel on turns. Water may leak on passenger floor area on left hand turn. DIAGNOSIS: 1. Remove instrument panel top cover and cluster bezel assembly by lifting up on the bottom outer areas of the cluster bezel and along the rearward edge to disengage the clips. Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel. 2. Remove both right and left A-Pillar trim moldings by pulling outward on the molding to disengage clips. 3. Run water on the windshield starting at the bottom and working up around the sides and around the top of the glass. Inspect for water dripping or running down the A-Pillars or front part of the windshield through the urethane bead. If a windshield water leak is found, repair as necessary before proceeding to the repair procedure. PARTS REQUIRED: AR 4318088 Butyl Rubber Sealer (Or Equivalent) AR 4467708 Silicone Windshield & Glass Sealer (Or Equivalent) AR 4655021 Cowl Screen Assembly (With Lip Seal) AR 4783100 Cowl Drain Tube AR 4655604 Cowl Top Patch REPAIR PROCEDURE: This bulletin involves sealing the cowl plenum, installing a cowl screen, and a cowl plenum drain tube. 1. On the inside of the vehicle, on the left top corner of the dash, fold back the cowl top silencer pad and temporarily retain it under the VIN plate pad on the instrument panel. Fold back the cowl top patch to gain access to the dash panel access hole. Refer to Figures 1 and 2. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8917 2. Look through the access hole in the cowl top and inspect for any water remaining in the cowl plenum. Remove any water that is present by using a vacuum through the access hole. Refer to Figure 1. 3. Remove the wiper arm assemblies. 4. Open the hood and remove the cowl-to-hood seal and the cowl screen assembly. 5. Disconnect the Wiper motor electrical connector and the three bolts holding the wiper assembly then remove the wiper motor assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8918 6. Apply Butyl Rubber Sealer P/N 4318088 (Or Equivalent) to the following areas of the cowl plenum. Refer to Figure 2, 3 and 4. A. Horizontal & vertical seams in the cowl plenum. B. Upper corner of the cowl plenum to cowl top extension (Right and Left sides). C. Bottom corner of A-Pillar transition (Right and Left sides). D. Horizontal and vertical seams under hood hinge attachment area (Right and Left sides.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8919 7. Force Silicone Windshield & Glass Sealer, P/N 4467708 (Or Equivalent), beneath the windshield edge to seal possible sheet metal leak covered by glass. Refer to Figure 4. 8. Install the wiper motor assembly. 9. Install a new Cowl Screen Assembly, P/N 4655021. 10. Install the wiper arm assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 8920 11. Ensure drain tube is properly installed (Fig 5). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation Wheels: All Technical Service Bulletins Control Arm Bushings - Steering Wheel Oscillation NO: 22-01-95 GROUP: Wheels & Tires DATE: Jan. 27, 1995 SUBJECT: Smooth Road Steering Wheel Oscillation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 3, 1995 (MDH 1-03-XX). SYMPTOM/CONDITION: A smooth road steering wheel oscillation/vibration back and forth may be observed when driving above 50 MPH. PARTS REQUIRED: AR 4509719 Bushing, Front Lower Control Arm Rear DIAGNOSIS/REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8930 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8931 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8932 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8933 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8943 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8944 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8945 Use the flow charts for diagnosis and correction: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dynamic Check. Visual Insp. & Road Test 22-40-02-93...................................................................... ............................................................................................................................................0.6 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, and 2nd Road Test 22-40-02-94................ .............................................................................................................................................................. ....................................1.3 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test. Align Front End 22-40-0295.......................................................................................................................................................... ........................................................2.0 Hrs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 220195 > Jan > 95 > Control Arm Bushings - Steering Wheel Oscillation > Page 8946 Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing. and 3rd Road Test 22-40-02-96............................................................. .....................................................................................................................................................3.4 Hrs. Dynamic Check, Visual Insp., Road Test, Balance Tires, 2nd Road Test, Align Front End & Install Lower Control Arm Bushing, 3rd Road Test, and Chec 22-40-02-97................................................... .............................................................................................................................................................. .5.4 Hrs. Match Mount Tire/Wheel Assembly (Ea. Wheel/Tire Assembly) 22-40-02-98..................................... .............................................................................................................................................................. ...............0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair Front Door Handle: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. Front Door Outside Handle 4. Remove nut holding door handle retainer to outer door panel. 5. Separate retainer from back of door handle. 6. Separate door handle from vehicle. INSTALLATION 1. Position door handle into door and install retainer at back of handle. 2. Install nut holding door handle retainer to outer door panel. 3. Connect lock and latch rods to door latch. 4. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments Door Latch Adjustment FRONT DOOR LATCH ADJUSTMENT 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 8956 Front Door Latch: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. Front Door Latch 3. Disconnect lock and latch rods from door latch. 4. Disengage wire connector from power door lock motor, if equipped. 5. Remove screws holding latch to door end frame. 6. Separate door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to re-open. 1. Position door latch inside door and install screws holding latch to door end frame. 2. Engage wire connector into power door lock motor, if so equipped. 3. Connect latch and lock rods to door latch. 4. Install door trim panel and water shield. 5. Adjust door latch using procedure in this section. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models Front Door Panel: Service and Repair Front Door Trim-2 Door Models REMOVAL 1. Release door latch and open door. 2. Lower door glass. Front Door Pull Cup 3. Remove screw inside pull cup holding door trim panel to bracket. 4. Pull and hold inside door handle away from door trim. Inside Door Handle Screw 5. Remove screw holding trim panel to door from behind inside door handle. Window Crank 6. Remove window regulator crank, if so equipped. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 8961 Door Trim Panel 7. Disengage hidden clips holding trim panel to door from around perimeter of trim panel. 8. Tilt trim panel outward to clear locator pins on backside of trim panel. 9. Disengage trim panel from retainer channel at the top of the door. Inside Door Handle Linkage 10. Move trim panel away from door and disengage clip holding door latch linkage to back of inside door handle. 11. Separate latch rod from handle. 12. Disengage wire connector from power door lock switch, mirror switch, and power window switch, if so equipped. 13. Separate trim panel from vehicle. INSTALLATION 1. Replace any damaged or missing push-in fasteners from around perimeter of door trim panel. 2. Place trim panel near door. 3. Engage wire connector to power lock switch, mirror switch, and power window switch, if so equipped. 4. Attach latch rod to inside door handle. 5. Engage clip holding door latch linkage to back of inside door handle. 6. Engage trim panel into retainer channel at top of door. 7. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 8. Engage hidden clips holding trim panel to door from around perimeter of trim panel. 9. With the window in the down position, orientate the window regulator crank handle appropriately Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if so equipped. 10. Install screw holding trim panel to door from behind inside door handle. 11. Install screw inside pull cup holding door trim panel to bracket. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 8962 Front Door Panel: Service and Repair Front Door Trim-4 Door Models REMOVAL 1. Release door latch and open door. Window Crank 2. Remove window regulator crank, if so equipped. Front Door Trim 3. Remove screw from inside arm rest pull cup. 4. Remove screw form behind inside latch release handle. 5. Disengage push-in fasteners holding trim to door panel around perimeter of trim panel. 6. Tilt trim panel outward to clear locator pins on backside of trim panel. 7. Disengage trim panel from retainer channel at top of door. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 8963 Inside Door Handle Linkage 8. Move trim panel away from door and disengage clip holding latch rod to handle. 9. Separate latch rod from handle. 10. Disengage wire connector from power door lock switch, mirror switch, and power window switch if so equipped. 11. Separate trim panel from door. INSTALLATION 1. Replace any damaged or missing push-in fasteners from around perimeter of door trim panel. 2. Place trim panel near door. 3. Engage wire connector into power door lock switch, mirror switch, and power window switch, if so equipped. 4. Insert latch rod into handle and engage clip. 5. Engage trim panel into retainer channel at top of door. 6. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 7. Engage push-in fasteners to bold trim to door panel around perimeter of trim panel. 8. Install screw behind inside latch release handle. 9. Install screw inside arm rest pull cup. 10. With the window in the down position, orientate the window regulator crank handle appropriately. Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if so equipped. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 8964 Front Door Panel: Service and Repair Front Door Water Shield REMOVAL 1. Remove door trim panel. 2. Remove Door speaker, if equipped. 3. Remove door trim pull cup mount bracket. 4. Disengage clip holding lock linkage to lock button bell crank. Water Shield 5. Peel water shield away from adhesive around perimeter of inner door panel. INSTALLATION 1. Insure that enough adhesive remains to securely retain the watershield. Replace as necessary. 2. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Engage clip holding lock linkage to lock button bell-crank. 4. Install door trim pull cup mount bracket. 5. Install door speaker, if equipped. 6. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 8968 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 8969 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner and outer door belt weatherstrips. 3. Loosen inner belt stabilizer. 4. Lower door glass to bottom of travel to access glass attachment bolts. Regulator Lift Channel 5. Remove bolts holding regulator lift channel to door glass. Guide Bolts 6. Remove bolts holding rear guide plate to door glass. 7. Separate rear guide plate from door glass. Door Glass Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 8973 8. Lift door glass upward and out of opening at top of door. 9. Remove front guide plate from door glass. INSTALLATION 1. Install front guide plate to door glass. 2. Carefully lower door glass through opening in top of door. 3. Position rear guide plate onto door glass and install bolts. 4. Install nuts holding regulator lift channel to door glass. 5. Tighten all door glass fasteners. 6. Tighten window inner belt stabilizer. 7. Install inner and outer door belt weatherstrips. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments Door Latch Adjustment 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments > Page 8978 Rear Door Latch: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. 4. Disengage wire connector from power door lock motor, if equipped. Rear Door Latch 5. Remove screws holding latch to door end frame. 6. Separate door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to open. 1. Position door latch on vehicle and install screws holding latch to door end frame. 2. Engage wire connector to power door lock motor, if so equipped. 3. Connect lock and latch rods to door latch. 4. Install watershield and door trim panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair Front Door Trim REMOVAL 1. Release door latch and open door. 2. Remove window regulator crank, if equipped. 3. Remove screw from inside arm rest pull cup. 4. Remove screw form behind inside latch release handle. 5. Disengage push-in fasteners holding trim to door panel around perimeter of trim panel. 6. Disengage trim panel from retainer channel at top of door. 7. Tilt top of trim panel away from door and disengage clip holding latch rod to handle. 8. Separate latch rod from handle. 9. Separate trim panel from door. INSTALLATION 1. Replace any damaged or missing push-in fasteners from around perimeter of door trim panel. 2. Place trim panel in position on door. 3. Insert latch rod into handle and engage clip. 4. Engage trim panel into retainer channel at top of door. 5. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 6. Engage push-in fasteners to hold trim to door panel around perimeter of trim panel. 7. Install screw behind inside latch release handle. 8. Install screw inside arm rest pull cup. 9. Install window regulator crank, if equipped. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Page 8985 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Page 8986 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner door belt weatherstrip. 3. Loosen door glass jounce bumper. 4. Lower door glass to bottom of door. Rear Door Glass 5. Remove nuts holding door glass to window regulator lift plate. 6. Disengage door glass from regulator. 7. Lift door glass upward out of the opening at the top of door. INSTALLATION 1. Lower door glass through opening in top of door and into position in the window regulator. 2. Install nuts holding door glass to window regulator lift plate. 3. Raise glass and tighten window inner belt stabilizer. 4. Install inner door belt weatherstrip, watershield and door trim panel. 5. Operate window and check for interference. Adjust glass as necessary Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Support Rod > Component Information > Technical Service Bulletins > Customer Interest for Hood Support Rod: > 239394 > Dec > 94 > Hood Prop Rod - Rattles Hood Support Rod: Customer Interest Hood Prop Rod - Rattles NO: 23-93-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: Hood Prop Rod Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 10/5/94 (MDH 10-05-XX). SYMPTOM/CONDITION: Customer complaint of "metallic" type rattle in the front end of the vehicle. The rattle usually occurs when the vehicle is driven over rough road surfaces. DIAGNOSIS: Open the hood and pull up on the hook end of the prop rod and remove it from its hold down. Inspect the radiator closure panel under where the hook end rests. If the paint is worn away or chipped, proceed to the repair procedure. PARTS REQUIRED: 1 4783133 Hood Prop Rod REPAIR PROCEDURE: This bulletin involves replacing the hood prop rod with a revised part. 1. Open the hood and support it with a rod, other than the prop rod. 2. Remove the two bolts from the hinge end of the prop rod. Pull up on the hook end and remove the prop rod from the vehicle. 3. Install hood prop rod, P/N 4783133. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-40-28-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Support Rod > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Support Rod: > 239394 > Dec > 94 > Hood Prop Rod - Rattles Hood Support Rod: All Technical Service Bulletins Hood Prop Rod - Rattles NO: 23-93-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: Hood Prop Rod Rattle MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 10/5/94 (MDH 10-05-XX). SYMPTOM/CONDITION: Customer complaint of "metallic" type rattle in the front end of the vehicle. The rattle usually occurs when the vehicle is driven over rough road surfaces. DIAGNOSIS: Open the hood and pull up on the hook end of the prop rod and remove it from its hold down. Inspect the radiator closure panel under where the hook end rests. If the paint is worn away or chipped, proceed to the repair procedure. PARTS REQUIRED: 1 4783133 Hood Prop Rod REPAIR PROCEDURE: This bulletin involves replacing the hood prop rod with a revised part. 1. Open the hood and support it with a rod, other than the prop rod. 2. Remove the two bolts from the hinge end of the prop rod. Pull up on the hook end and remove the prop rod from the vehicle. 3. Install hood prop rod, P/N 4783133. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-40-28-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Trunk Latch REMOVAL 1. Release trunk lid latch and open trunk lid. 2. Remove bolts holding trunk latch to trunk lid. 3. Separate trunk latch from trunk lid. 4. Disconnect remote trunk latch release cable from trunk latch. 5. Disengage trunk ajar switch connector from latch. 6. Separate latch from vehicle. INSTALLATION 1. Position latch in vehicle and engage trunk ajar switch connector to latch. 2. Connect remote trunk latch release cable to trunk latch. 3. Install bolts holding trunk latch to trunk lid. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Trunk Lock Cylinder 1. Remove trunk latch. 2. Remove clip holding trunk lock cylinder to trunk lid. 3. Pull lock cylinder from trunk lid. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Emergency Trunk Release - Availability Trunk / Liftgate Release Lever: Technical Service Bulletins Emergency Trunk Release - Availability NUMBER: 23-02-00 GROUP: Body DATE: Feb. 4, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-20-99 REV. A DATED AUGUST 13, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS INFORMATION. SUBJECT: Internal Emergency Trunk Release MODELS: 1995 - 2000 (JA) Breeze/Cirrus/Stratus 1996 - 2000 (JX) Sebring Convertible **1993 2000 (LH) Concorde/Intrepid/LHS/New Yorker/Vision/300M** 1995 - 2000 (PL) Neon NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO INSTALL AN INTERNAL EMERGENCY TRUNK RELEASE. RELEASE INSTALLATION EXPENSE IS SHARED BY DAIMLERCHRYSLER AND THE CUSTOMER. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE LABOR ONLY. THE CUSTOMER IS RESPONSIBLE FOR THE PART EXPENSE. REFER TO WARRANTY BULLETIN D-99-20 FOR CLAIMING THE LABOR EXPENSE. DISCUSSION: DaimlerChrysler Corporation is now offering internal emergency trunk releases for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the parts are available. The trunk releases are packaged in a kit containing all necessary parts and a detailed instruction sheet. PARTS REQUIRED: 1 05016812AA Kit, Emergency Trunk Release, 1995 - 2000 JA **1 05016813AA Kit, Emergency Trunk Release, 1993 - 1997 LH** 1 05016810AA Kit, Emergency Trunk Release, 1998 - 2000 LH 1 05016809AA Kit, Emergency Trunk Release, 2000 PL W/Remote Entry 1 05016811AA Kit, Emergency Trunk Release, 1994 - 1999 PL, 2000 PL W/Manual Entry 1 05016814AA Kit, Emergency Trunk Release, 1996 - 2000 JX POLICY: Customer Satisfaction Announcement TIME ALLOWANCE: Labor Operation No. 23-41-25-95 ......................................................................................................................................... .............................. 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Technical Service Bulletins > Customer Interest for Front Fender Liner: > 239994 > Dec > 94 > Front Fender Inner Splash Shield - Rattles Front Fender Liner: Customer Interest Front Fender Inner Splash Shield - Rattles NO: 23-99-94 GROUP: Body DATE: Dec. 30, 1994 SUBJECT: Front Fender Inner Splash Shield Rattle MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Rattle in right and/or left front fender area while driving. Front fender inner splash shield loose or flapping. DIAGNOSIS: Inspect both front fender inner splash shield attachments to the front fender. If the splash shields are loose and/or the plastic fasteners are damaged or missing, proceed to the repair procedure. PARTS REQUIRED: 1 4783116 Front Fender Cap, Right Side 1 4783117 Front Fender Cap, Left Side 4 6035204 Screws 4 6032031 U-Nuts REPAIR PROCEDURE: This bulletin involves installing fender caps on both front fenders. 1. Remove the two lower plastic fasteners from each front fender splash shields. 2. Install two U-nuts, P/N 6032031, on the fender flange behind each splash shield. 3. Install fender cap, P/N 4783116 (Right Side), and P/N 4783117 (Left Side), over the fender splash shield. 4. Fasten each fender cap to the fender with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Cap. Wheel Opening. Fender. Install. Right/Left Labor Operation No: 23-02-59-92/93..................................................................................................................................... ................................0.2 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Fender Liner: > 239994 > Dec > 94 > Front Fender Inner Splash Shield - Rattles Front Fender Liner: All Technical Service Bulletins Front Fender Inner Splash Shield - Rattles NO: 23-99-94 GROUP: Body DATE: Dec. 30, 1994 SUBJECT: Front Fender Inner Splash Shield Rattle MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Rattle in right and/or left front fender area while driving. Front fender inner splash shield loose or flapping. DIAGNOSIS: Inspect both front fender inner splash shield attachments to the front fender. If the splash shields are loose and/or the plastic fasteners are damaged or missing, proceed to the repair procedure. PARTS REQUIRED: 1 4783116 Front Fender Cap, Right Side 1 4783117 Front Fender Cap, Left Side 4 6035204 Screws 4 6032031 U-Nuts REPAIR PROCEDURE: This bulletin involves installing fender caps on both front fenders. 1. Remove the two lower plastic fasteners from each front fender splash shields. 2. Install two U-nuts, P/N 6032031, on the fender flange behind each splash shield. 3. Install fender cap, P/N 4783116 (Right Side), and P/N 4783117 (Left Side), over the fender splash shield. 4. Fasten each fender cap to the fender with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Cap. Wheel Opening. Fender. Install. Right/Left Labor Operation No: 23-02-59-92/93..................................................................................................................................... ................................0.2 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Fender Liner: > Page 9030 Front Fender Liner: By Symptom Technical Service Bulletin # 239994 Date: 941230 Front Fender Inner Splash Shield - Rattles NO: 23-99-94 GROUP: Body DATE: Dec. 30, 1994 SUBJECT: Front Fender Inner Splash Shield Rattle MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Rattle in right and/or left front fender area while driving. Front fender inner splash shield loose or flapping. DIAGNOSIS: Inspect both front fender inner splash shield attachments to the front fender. If the splash shields are loose and/or the plastic fasteners are damaged or missing, proceed to the repair procedure. PARTS REQUIRED: 1 4783116 Front Fender Cap, Right Side 1 4783117 Front Fender Cap, Left Side 4 6035204 Screws 4 6032031 U-Nuts REPAIR PROCEDURE: This bulletin involves installing fender caps on both front fenders. 1. Remove the two lower plastic fasteners from each front fender splash shields. 2. Install two U-nuts, P/N 6032031, on the fender flange behind each splash shield. 3. Install fender cap, P/N 4783116 (Right Side), and P/N 4783117 (Left Side), over the fender splash shield. 4. Fasten each fender cap to the fender with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Cap. Wheel Opening. Fender. Install. Right/Left Labor Operation No: 23-02-59-92/93..................................................................................................................................... ................................0.2 Hrs. FAILURE CODE: PS - New Part Technical Service Bulletin # 239994 Date: 941230 Front Fender Inner Splash Shield - Rattles NO: 23-99-94 GROUP: Body DATE: Dec. 30, 1994 SUBJECT: Front Fender Inner Splash Shield Rattle MODELS: 1995 (PL) Neon Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Fender Liner: > Page 9031 SYMPTOM/CONDITION: Rattle in right and/or left front fender area while driving. Front fender inner splash shield loose or flapping. DIAGNOSIS: Inspect both front fender inner splash shield attachments to the front fender. If the splash shields are loose and/or the plastic fasteners are damaged or missing, proceed to the repair procedure. PARTS REQUIRED: 1 4783116 Front Fender Cap, Right Side 1 4783117 Front Fender Cap, Left Side 4 6035204 Screws 4 6032031 U-Nuts REPAIR PROCEDURE: This bulletin involves installing fender caps on both front fenders. 1. Remove the two lower plastic fasteners from each front fender splash shields. 2. Install two U-nuts, P/N 6032031, on the fender flange behind each splash shield. 3. Install fender cap, P/N 4783116 (Right Side), and P/N 4783117 (Left Side), over the fender splash shield. 4. Fasten each fender cap to the fender with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Cap. Wheel Opening. Fender. Install. Right/Left Labor Operation No: 23-02-59-92/93..................................................................................................................................... ................................0.2 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest for Firewall: > 232694 > Mar > 94 > Steering Column Dash Seal - Noise To The Interior Firewall: Customer Interest Steering Column Dash Seal - Noise To The Interior NO: 23-26-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Engine Noise In Passenger Compartment MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Excessive engine noise coming from the under the dash on the drivers side of the vehicle. DIAGNOSIS: Visually inspect the lower steering column dash seal to dash cover. If it is not fully seated, proceed with the repair procedure. See Illustration. REPAIR PROCEDURE: This bulletin involves re-installing the lower steering column dash seal to dash cover. Re-install the lower steering column dash seal to dash cover. Make sure the entire circumference is seated in the groove on the dash cover, and seal is not cut, ripped, or deformed. Replace the seal if it is damaged. POLICY:Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-11-41-90 0.2 Hrs. FAILURE CODE: 51- Improperly Installed Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Firewall: > 232694 > Mar > 94 > Steering Column Dash Seal - Noise To The Interior Firewall: All Technical Service Bulletins Steering Column Dash Seal - Noise To The Interior NO: 23-26-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Engine Noise In Passenger Compartment MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Excessive engine noise coming from the under the dash on the drivers side of the vehicle. DIAGNOSIS: Visually inspect the lower steering column dash seal to dash cover. If it is not fully seated, proceed with the repair procedure. See Illustration. REPAIR PROCEDURE: This bulletin involves re-installing the lower steering column dash seal to dash cover. Re-install the lower steering column dash seal to dash cover. Make sure the entire circumference is seated in the groove on the dash cover, and seal is not cut, ripped, or deformed. Replace the seal if it is damaged. POLICY:Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-11-41-90 0.2 Hrs. FAILURE CODE: 51- Improperly Installed Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 9054 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 9060 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 232294 > Mar > 94 > Carpet - Separates From Backing Carpet: Customer Interest Carpet - Separates From Backing NO: 23-22-94 GROUP: Body DATE: Mar. 11, 1994 SUBJECT: Carpet Pile Separates From Backing MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 2/14/94, MDH 0214XX. SYMPTOM/CONDITION: The carpet pile separates from the backing material in patches leaving bare spots. This occurs primarily in the tunnel formation area. DIAGNOSIS: Using your fingers, pull on the pile in a formed area or an area of the carpet with a vertical surface. If the carpet pile pulls out easily in little tufts (without the use of pliers or other gripping tool) proceed with the following repair. PARTS REQUIRED: AR LC63PD5 Carpet (Quartz) w/Cable Operated Deck Lid Release AR LC62PD5 Carpet (Quartz) w/o Cable Operated Deck Lid Release AR LC63PF7 Carpet (Driftwood) w/Cable Operated Deck Lid Release AR LC62PF7 Carpet (Driftwood) w/o Cable Operated Deck Lid Release REPAIR PROCEDURE: This bulletin involves replacing the carpet with a revised part. 1. Remove the front seats, rear seat cushion, front and rear seat belt lower anchor bolts, deck lid remote release mechanism (if so equipped), cowl trim covers, front and rear door sill trim covers, and center floor console as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 23-20 through 23-25. NOTE: DO NOT LIFT THE INSTRUMENT PANEL TO REMOVE OR INSTALL THE CARPET AS THIS MAY RESULT IN DAMAGE TO THE HEATER/AIR CONDITIONING UNIT AND INSTRUMENTATION AND MAY CAUSE UNNECESSARY BUZZ, SQUEAKS OR RATTLES. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 232294 > Mar > 94 > Carpet - Separates From Backing > Page 9070 2. Cut the carpet in three places - under the instrument panel in the middle of the tunnel formation, under the shifter and under the shifter cables (See Illustration). 3. Loosen the bottom of the B-Pillar trim molding by disengaging the bottom two push clips and pull the carpet out from underneath. Fold carpet in half toward rear seat and remove carpet through rear door opening. 4. Obtain a new carpet as called out in the parts section. Before installing the new carpet, it will be necessary to cut the replacement carpet along the mold line on the underside of the tunnel formation and in the areas of the shifter and shifter cables. 5. Install the carpet in the car making sure to stuff the carpet in the cut areas under the instrument panel, shifter and shifter cables. Push the carpet under both B-Pillar trim moldings and re-secure the moldings to the B-Post. 6. Hook the carpet at the four points along both sides over the sill frame. Re-install all trim covers, center console, seat belt attachments and seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-21-15-90 1.0 Hrs. FAILURE CODE: 01 - Adhesive Bond Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232294 > Mar > 94 > Carpet - Separates From Backing Carpet: All Technical Service Bulletins Carpet - Separates From Backing NO: 23-22-94 GROUP: Body DATE: Mar. 11, 1994 SUBJECT: Carpet Pile Separates From Backing MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 2/14/94, MDH 0214XX. SYMPTOM/CONDITION: The carpet pile separates from the backing material in patches leaving bare spots. This occurs primarily in the tunnel formation area. DIAGNOSIS: Using your fingers, pull on the pile in a formed area or an area of the carpet with a vertical surface. If the carpet pile pulls out easily in little tufts (without the use of pliers or other gripping tool) proceed with the following repair. PARTS REQUIRED: AR LC63PD5 Carpet (Quartz) w/Cable Operated Deck Lid Release AR LC62PD5 Carpet (Quartz) w/o Cable Operated Deck Lid Release AR LC63PF7 Carpet (Driftwood) w/Cable Operated Deck Lid Release AR LC62PF7 Carpet (Driftwood) w/o Cable Operated Deck Lid Release REPAIR PROCEDURE: This bulletin involves replacing the carpet with a revised part. 1. Remove the front seats, rear seat cushion, front and rear seat belt lower anchor bolts, deck lid remote release mechanism (if so equipped), cowl trim covers, front and rear door sill trim covers, and center floor console as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pgs. 23-20 through 23-25. NOTE: DO NOT LIFT THE INSTRUMENT PANEL TO REMOVE OR INSTALL THE CARPET AS THIS MAY RESULT IN DAMAGE TO THE HEATER/AIR CONDITIONING UNIT AND INSTRUMENTATION AND MAY CAUSE UNNECESSARY BUZZ, SQUEAKS OR RATTLES. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232294 > Mar > 94 > Carpet - Separates From Backing > Page 9076 2. Cut the carpet in three places - under the instrument panel in the middle of the tunnel formation, under the shifter and under the shifter cables (See Illustration). 3. Loosen the bottom of the B-Pillar trim molding by disengaging the bottom two push clips and pull the carpet out from underneath. Fold carpet in half toward rear seat and remove carpet through rear door opening. 4. Obtain a new carpet as called out in the parts section. Before installing the new carpet, it will be necessary to cut the replacement carpet along the mold line on the underside of the tunnel formation and in the areas of the shifter and shifter cables. 5. Install the carpet in the car making sure to stuff the carpet in the cut areas under the instrument panel, shifter and shifter cables. Push the carpet under both B-Pillar trim moldings and re-secure the moldings to the B-Post. 6. Hook the carpet at the four points along both sides over the sill frame. Re-install all trim covers, center console, seat belt attachments and seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-21-15-90 1.0 Hrs. FAILURE CODE: 01 - Adhesive Bond Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > NHTSA97V169000 > Oct > 97 > Recall 97V169000: Steering Column Coupler May Disconnect Steering Shaft Coupler: All Technical Service Bulletins Recall 97V169000: Steering Column Coupler May Disconnect The steering column coupler can become disconnected when the vehicle experiences an underbody impact. Loss of steering control can occur. Dealers will replace the steering column coupler with a coupler design that collapses on impact. Owner notification is expected to begin during November 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 9087 Carpet: Service and Repair Carpet REMOVAL 1. Remove front seats. 2. Remove rear seat cushion. 3. Remove bolts holding rear seat belt lower anchors to floor. 4. Remove bolts holding front seat belt lower anchors to floor. 5. Remove bolts holding front seat belt buckles to floor. 6. Remove door sill trim covers. 7. Remove cowl trim covers. 8. Remove center floor console. 9. Remove lower fasteners from B-pillar trim panel. 10. Pull carpet from behind trim panel. 11. Fold carpet in half toward rear seat. 12. Remove carpet through rear door opening. INSTALLATION 1. Install carpet through rear door opening. 2. Unfold carpet. 3. Thick carpet behind trim panel. 4. Install lower fasteners holding B-pillar trim panel. 5. Install center floor console. 6. Install cowl trim covers. 7. Install door sill trim covers. 8. Install bolts holding front seat belt buckles to floor. 9. Install bolts holding front seat belt lower anchors to floor. 10. Install bolts holding rear seat belt lower anchors to floor. 11. Install rear seat cushion. 12. Install front seats. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: Customer Interest Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: All Technical Service Bulletins Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 9101 Console: Service and Repair Floor Console REMOVAL 1. Fully apply parking brake. 2. Remove screw cover plugs over screws just rearward of cupholders. 3. Remove screws holding console to floor bracket just rearward of cupholders. 4. Open console storage compartment lid, if so equipped. 5. Remove screw cover plugs over screws near rear of console, if vehicle is equipped with a non-armrest console. 6. Remove screws holding console to floor bracket. 7. Remove shift lever knob, if vehicle is equipped with a manual transmission. 8. Lift console upward over gear selector and park brake handle. 9. Separate console from vehicle. INSTALLATION 1. Move floor console into position in vehicle. 2. Install screws holding console to floor brackets. 3. Install screw cover plugs. 4. Install shift lever knob, if vehicle is equipped with a manual transmission. 5. Release parking brake and close console storage compartment lid, if so equipped. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 9108 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair REMOVAL 1. Remove screws holding sun visor to roof header panel. 2. Disengage wire connector from lighted vanity mirror, if so equipped. 3. Separate sun visors from vehicle. 4. Remove A-pillar trim covers. 5. Remove B-pillar trim panels, if vehicle is a 4 door. 6. Remove (upper) quarter panel trim panels. 7. Remove assist handles, if so equipped. 8. Remove sun visor hooks. 9. Remove coat hooks, if vehicle is a 4 door. 10. If vehicle is equipped with a sunroof; a. Open sunroof. Sunroof Opening Trim Welt b. Remove trim welt around sunroof opening. c. Remove sunroof switch pod. d. Disconnect sunroof switch pod wire connectors. e. Remove screw holding switch pod retainer to roof. 11. Remove push-in fastener at rear of headlining. 12. Disengage dome lamp wire connector, at rear of headlining. 13. Remove push-in fastener holding wiring to C-pillar. Headlining 14. Remove headlining through door opening. INSTALLATION 1. Position headlining in vehicle. 2. Install sun visor hooks. 3. Install coat hooks, if vehicle is a 4 door. 4. Install push-in fastener at rear of headlining. 5. install assist handles, if so equipped. 6. Install push-in fastener holding headliner wiring to C-pillar. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9112 7. Engage dome lamp wire connector, at rear of headlining. 8. If vehicle is equipped with a sunroof; a. Install screw holding switch pod retainer to roof. b. Connect sunroof switch pod wire connectors. c. Install sunroof switch pod. Sunroof Opening Trim Welt d. Install trim welt around sunroof opening. e. Close sunroof. 9. Install (upper) quarter panel trim panel. 10. Install B-pillar trim panels, if vehicle is a 4 door. 11. Install A-pillar trim covers. 12. Install sun visors, lighted vanity mirror wire connector, if so equipped, and screws holding sun visors to roof header panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Trim Panel: Service and Repair A-Pillar Trim A-Pillar Trim REMOVAL 1. Remove instrument panel top cover. 2. Disengage clips holding trim to A-pillar. 3. Separate A-pillar trim from vehicle. INSTALLATION 1. Position A-pillar trim panel to A-pillar. 2. Align locating pins on backside of trim panel to mating holes in A-pillar. 3. Push clips on trim panel into slots in A-pillar. 4. Install instrument panel top cover. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9117 Trim Panel: Service and Repair B-Pillar Trim-4 Door B-Pillar Trim REMOVAL 1. Remove bolt holding lower seat belt anchor to floor pan kick-up. 2. Remove shoulder belt height control knob. 3. Remove bolt holding turning loop to belt adjuster. 4. Remove access cover from B-pillar trim. 5. Disengage clips holding trim to B-pillar. 6. Feed seat belt turning loop and seat belt through trim panel. 7. Separate B-pillar trim from vehicle. INSTALLATION 1. Position B-pillar trim panel near B-pillar. 2. Feed seat belt turning loop and seat belt through trim panel. 3. Align locating pins on backside of trim panel to mating holes in B-pillar. 4. Push clips on trim panel into slots in B-pillar. 5. Install access cover to B-pillar trim. 6. Install bolt holding turning loop to belt adjuster. 7. Install shoulder belt height control knob. 8. Install bolt holding lower seat belt anchor to floor pan kick-up. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9118 Trim Panel: Service and Repair Cowl Side Trim Panel Side Cowl Trim REMOVAL 1. Disengage clips holding cowl trim to cowl side panel. 2. Separate cowl trim from vehicle. INSTALLATION 1. Position cowl trim panel to inner cowl panel. 2. Align locating pins on backside of cowl trim panel to mating holes in inner cowl panel. 3. Push clips on trim panel into slots in inner cowl panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9119 Trim Panel: Service and Repair Door Opening Trim Welt Door Opening Trim Welt REMOVAL 1. Open door to gain access to trim welt. 2. Remove door sill trim panel. 3. Pull trim welt from door opening flange. INSTALLATION 1. Locate paint dot on backside of trim welt. 2. Position trim welt to vehicle with paint dot in the appropriate position. 3. Press trim welt onto door opening flange starting at the paint dot position. 4. Install door sill trim panel Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9120 Trim Panel: Service and Repair A-Pillar Trim A-Pillar Trim REMOVAL 1. Remove instrument panel top cover. 2. Disengage clips holding trim to A-pillar. 3. Separate A-pillar trim from vehicle. INSTALLATION 1. Position A-pillar trim panel to A-pillar. 2. Align locating pins on backside of trim panel to mating holes in A-pillar. 3. Push clips on trim panel into slots in A-pillar. 4. Install instrument panel top cover. B-Pillar Trim-4 Door B-Pillar Trim REMOVAL 1. Remove bolt holding lower seat belt anchor to floor pan kick-up. 2. Remove shoulder belt height control knob. 3. Remove bolt holding turning loop to belt adjuster. 4. Remove access cover from B-pillar trim. 5. Disengage clips holding trim to B-pillar. 6. Feed seat belt turning loop and seat belt through trim panel. 7. Separate B-pillar trim from vehicle. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9121 INSTALLATION 1. Position B-pillar trim panel near B-pillar. 2. Feed seat belt turning loop and seat belt through trim panel. 3. Align locating pins on backside of trim panel to mating holes in B-pillar. 4. Push clips on trim panel into slots in B-pillar. 5. Install access cover to B-pillar trim. 6. Install bolt holding turning loop to belt adjuster. 7. Install shoulder belt height control knob. 8. Install bolt holding lower seat belt anchor to floor pan kick-up. Cowl Side Trim Panel Side Cowl Trim REMOVAL 1. Disengage clips holding cowl trim to cowl side panel. 2. Separate cowl trim from vehicle. INSTALLATION 1. Position cowl trim panel to inner cowl panel. 2. Align locating pins on backside of cowl trim panel to mating holes in inner cowl panel. 3. Push clips on trim panel into slots in inner cowl panel. Door Opening Trim Welt Door Opening Trim Welt REMOVAL 1. Open door to gain access to trim welt. 2. Remove door sill trim panel. 3. Pull trim welt from door opening flange. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9122 1. Locate paint dot on backside of trim welt. 2. Position trim welt to vehicle with paint dot in the appropriate position. 3. Press trim welt onto door opening flange starting at the paint dot position. 4. Install door sill trim panel Door Sill Trim Door Sill Trim REMOVAL 1. Open door to gain access to sill trim. 2. Disengage clips holding sill trim to door sill and door opening flange. 3. Separate door sill trim from vehicle. INSTALLATION 1. Position door sill trim on door sill. 2. Align locating pins on backside of trim panel to holes in door sill. 3. Engage clips on trim panel into slots in door sill. 4. Engage clips on trim panel onto door opening flange. 5. Press downward on trim panel to fully engage all clips. Lower Quarter Trim-4 Door Lower Quarter Trim REMOVAL 1. Remove upper quarter trim panel. 2. Remove rear seat cushion and back. 3. Disengage clips holding trim to lower quarter panel. 4. Remove seat belt from slot in trim panel. 5. Separate lower quarter trim from vehicle. INSTALLATION 1. Position lower quarter trim panel to vehicle. 2. Install seat belt to slot in trim panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9123 3. Align locating pins on backside of trim panel to mating holes in inner quarter panel. 4. Press clips on trim panel into slots in inner quarter panel. 5. Install rear seat back and cushion. 6. Install upper quarter trim panel. Parcel Shelf Trim Parcel Shelf Trim 1. Remove upper quarter trim from one side of vehicle. 2. Remove rear seat cushion and back. 3. Remove bolts holding rear seat shoulder belt lower anchors to floor pan. 4. Disengage seat belt bezel from parcel shelf. 5. Separate parcel shelf trim from vehicle. 6. Reverse the preceding operation for installation. Quarter Trim Panel-2 Door Quarter Trim Panel REMOVAL 1. Remove rear seat cushion and back. 2. Slide lower seat belt anchor cover up the webbing to expose the belt. 3. Remove bolt holding lower seat belt anchor to floor. 4. Separate seat belt from floor. 5. Remove screw holding coat hook to top of quarter trim panel. 6. Disengage hidden clips holding quarter trim panel to inner quarter panel. 7. Separate trim from quarter panel. 8. Feed seat belt webbing through access bole in trim panel. 9. Separate quarter trim panel from vehicle. INSTALLATION 1. Feed seat belt webbing through access hole in trim panel. 2. Position trim panel near inner quarter panel. 3. Align locating pins on backside of trim panel to mating holes in inner quarter panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 9124 4. Push clips on trim panel into slots in inner quarter panel starting with the clips located near locating pins. 5. Install screw holding coat hook to top of quarter trim panel. 6. Install bolt securing seat belt anchor to floor. 7. Slide lower seat belt anchor cover down to cover anchor bolt. 8. Install rear seat cushion and seat back. Side View Mirror Trim Cover Side View Mirror Trim Cover 1. Disengage clips holding side view mirror cover to stanchion. 2. Separate mirror cover from vehicle. 3. Reverse the preceding operation for installation. Upper Quarter Trim Door Upper Quarter Trim REMOVAL 1. Disengage clips holding trim to upper quarter panel. 2. Separate upper trim panel from vehicle. INSTALLATION 1. Check to ensure that electric rear window wiring is positioned correctly in the roof channel provided. 2. Position trim panel in vehicle. 3. Align locating pins on backside of trim panel to mating holes in upper quarter panel. 4. Push clips on trim panel into slots in upper quarter panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Door Lock Cylinder REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect door lock rod from latch. 4. Remove clip holding lock cylinder to door handle. 5. Pull lock cylinder from door handle. INSTALLATION 1. Push lock cylinder into door handle. 2. Install clip holding lock cylinder to door handle. 3. Connect door lock rod from latch. 4. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions Power Locks: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9134 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9135 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9136 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9137 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9138 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9139 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9140 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9141 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9142 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9143 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9144 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9145 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9146 Power Locks: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9147 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9148 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9149 Power Locks: Electrical Diagrams Power Door Locks (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Diagrams > Diagram Information and Instructions > Page 9150 Power Door Locks (Part 2 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Description and Operation > Power Door Locks Description Power Locks: Description and Operation Power Door Locks Description POWER DOOR LOCKS The Power Distribution Center (PDC) supplies voltage to the fuse block from the 40 amp HEADLAMPS fuse on circuit A3. Fuse 3, located in the fuse block, supplies battery voltage on the F35 circuit to both door lock switches. The ground path for the system is through the left door lock switch cavities 2 and 4 on the Z8 circuit. The grounding point is located at the instrument panel left center support brace. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Description and Operation > Power Door Locks Description > Page 9153 Power Locks: Description and Operation Door Switch Operation (LOCK) Left Door LEFT DOOR SWITCH OPERATION (LOCK) When the door lock switch is moved to the LOCK position, voltage is supplied on the P36 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P35 circuit. The P35 circuit goes to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit goes to its grounding point. Right Door RIGHT DOOR SWITCH OPERATION (LOCK) When the switch is moved to the LOCK position, voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P35 circuit. The P35 circuit goes to the left door switch and through to the Z8 circuit. The Z8 circuit then goes to the grounding point at the left center instrument panel support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Description and Operation > Power Door Locks Description > Page 9154 Power Locks: Description and Operation Door Switch Operation (UNLOCK) Left Door LEFT DOOR SWITCH OPERATION (UNLOCK) When the switch is moved to the UNLOCK position, voltage is supplied on the P35 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then goes to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit goes back to the right door switch, LOCK side, and passes through the internal bus bar to the P36 circuit. The P36 circuit goes back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Right Door RIGHT DOOR SWITCH OPERATION (UNLOCK) When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P36 to the left door switch. At the left door switch, the ground passes through that switches' internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > System Information > Description and Operation > Page 9155 Power Locks: Testing and Inspection ^ Check the 40 amp fuse in the Power Distribution Center (PDC). ^ Check the 15 amp fuse in cavity 3 of the fuse block. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Trunk Lock Cylinder 1. Remove trunk latch. 2. Remove clip holding trunk lock cylinder to trunk lid. 3. Pull lock cylinder from trunk lid. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions Mirrors: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9175 Mirrors: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9176 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9177 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9178 Mirrors: Electrical Diagrams Power Mirrors (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 9179 Power Mirrors (Part 2 Of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors Description Mirrors: Description and Operation Power Mirrors Description POWER MIRRORS The power mirrors use a single switch located in the left door trim panel. The feed for the system is supplied from the 10 amp interior lamps micro fuse located in the Power Distribution Center (PDC). This fuse also supplies power for the radio and interior lamps. Grounding for the power mirrors, along with power door locks and A/C Heater control, is provided through the Z8 circuit, which attaches to the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors Description > Page 9182 Mirrors: Description and Operation Switch and Mirror Operation SWITCH AND MIRROR OPERATION The power mirror switch has a right and a left position. Moving the switch to either of these positions changes the voltage path internal to the switch (changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a right door mirror movement LEFT is selected, voltage is supplied through the P94 circuit and the ground is passed through circuit F91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Page 9183 Mirrors: Testing and Inspection ^ Check the interior lamps 10 amp fuse located in the Power Distribution Center. ^ Circuit M1 supplies voltage to the radio, cargo lamp, underhood lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items. ^ Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror Mirrors: Service and Repair Inside Rear View Mirror Rear View Mirror 1. Using a wax pencil, locate and mark the mounting position of the button on the outside of the windshield. 2. If the vinyl pad had remained on the windshield glass, apply "low heat" to it with an electric heat gun until the vinyl softens; then peel the vinyl pad from the glass. 3. Thoroughly clean the inner surface of the windshield glass in the mounting area of the mirror button using a mild abrasive cleaning powder such as Ajax, Comet, or equivalent, on a clean cloth saturated with alcohol. Then, apply alcohol to a paper towel and wipe off any traces of remaining cleaner. 4. Thoroughly sand the windshield mounting surface (the side with least surface area) of the mirror button with a clean piece of fine grit sandpaper and wipe the surface clean with a clean paper towel saturated with alcohol. 5. Using kit 4054099 or equivalent, crush the vial in the plastic housing of the accelerator. This saturates the felt applicator. Remove paper sleeve. Apply a generous amount of accelerator on the mounting surface of the mirror button. 6. Allow the accelerator to dry for 5 minutes. Do not touch the mounting surface of the button or glass. 7. Apply a thin film of Accelerator to the inner surface of the windshield in the button mounting area. Allow one minute to dry. Do not touch the surface. 8. Apply one drop of Adhesive to the center of the windshield mounting surface of the mirror button and, using the bottom of the Adhesive tube, quickly distribute the adhesive evenly over the entire bonding surface of the button. 9. Position the bottom straight edge of the mirror button on the horizontal line and center it on the vertical line and press it firmly to the glass and apply pressure for about one minute. Proper location is essential as cement sets up very fast. 10. Allow five minutes for the adhesive to set; then, remove any excess adhesive residue from the windshield in the attachment area using an alcohol-dampened cloth. 11. Slide the mirror downward onto the button and tighten the screw. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror > Page 9186 Mirrors: Service and Repair Outside Rear View Mirror Side View Mirror Trim Cover SIDE VIEW MIRROR TRIM COVER 1. Disengage clips holding side view mirror cover to stanchion. 2. Separate mirror cover from vehicle. 3. Reverse the preceding operation for installation. SIDE VIEW MIRROR Removal 1. Remove side view mirror cover. 2. Remove door trim panel and water shield if equipped with power mirror. 3. Disengage wire connector from power mirror motor, if equipped. Side View Mirror 4. Remove bolts holding mirror to stanchion. 5. Separate mirror from vehicle. Installation 1. Position side view mirror on vehicle and install nuts attaching mirror to stanchion. 2. Engage wire connector from power window motor, if so equipped. 3. Install door trim panel and water shield, if equipped with power mirrors. 4. Install side view mirror trim cover. SIDE VIEW MIRROR STANCHION Removal 1. Remove side view mirror. 2. Remove bolt holding top of side view mirror stanchion to inner door panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror > Page 9187 Side View Mirror Stanchion 3. Remove bolts holding stanchion to outer door panel. 4. Remove nut holding stanchion jack-screw to inner door panel. 5. Disengage push-in fastener holding door opening weatherstrip to stanchion. 6. Separate stanchion from vehicle. Installation Reverse the preceding operation. Using a Snap-On flare-nut socket (FRXM10) and hex-wrench adjust the jack-screw at bottom of stanchion to achieve proper alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: Customer Interest Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 9197 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Paint: Customer Interest Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 9202 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: All Technical Service Bulletins Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 9208 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 239794 > Dec > 94 > Paint Anti Chip Film/Front Fender Cap Repair Paint: All Technical Service Bulletins Paint Anti Chip Film/Front Fender Cap - Repair NO: 23-97-94 GROUP: Body DATE: Dec. 16, 1994 SUBJECT: Paint Anti-Chip Film and Front Fender Cap Repair Procedure MODELS: 1995 (PL) Neon DISCUSSION: As a running change, vehicles have been built with paint anti-chip film on several areas of the rocker panels. Also, vehicles may be equipped with front fender end caps. The following is a repair procedure for these items. PARTS REQUIRED: AR 4783115 Left or Right Front Rocker Panel Anti-Chip Film AR 4797292 Lower Rocker Panel "Darts" Anti-Chip Film (Pkg. 6) AR 4783116 Right Front Fender End Cap AR 4783117 Left Front Fender End Cap AR 6035204 Retaining Screw (Fender End Cap) AR 6032031 U-Nut (Fender End Cap) REPAIR PROCEDURE: This bulletin involves replacing damaged paint anti-chip film and/or front fender end caps. 1. Locate the paint anti-chip film to be replaced on the rocker panel (See Illustration). 2. Starting at one corner and using a heat gun, apply heat and slowly peel back the paint anti-chip film. Remove any residual adhesive using a commercial remover such as 3M adhesive remover # 08908 or equivalent. Wipe off the panel with a soft cloth saturated with a cleaner such as 3M adhesive cleaner # 08984 or equivalent. NOTE: APPLICATION OF PAINT ANTI-CHIP FILM SHOULD BE DONE WHEN THE AIR AND SURFACE TEMPERATURES ARE BETWEEN 70~ AND 90~ F. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 239794 > Dec > 94 > Paint Anti Chip Film/Front Fender Cap Repair > Page 9213 3. Remove the backing from the paint anti-chip film. Spray the film and/or the application area with a 50.-50 solution of isopropyl alcohol and water. 4. When applying the rocker panel film, align the top of the film approximately 1/16 In. (3 mm) below the break line in the rocker panel and 1/16 In. (3 mm) from the fender break line. When applying the "dart" film, place the middle of the film over the rear indentation (See Illustration). 5. When replacing the fender caps, use the lower two holes in the front fender. The two u-nuts, P/N 6032031, are installed on the fender and the inner fender liner/splash shield is between the fender cap and fender. Attach in place with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Cap, Wheel Opening, Fender, Replace Right/Left 23-02-59-90/91 0.2 Hrs. Film, Anti-Chip, Replace, Right or Left 23-01-07-90 0.2 Hrs. Film, Anti-Chip ("Darts"), Replace All 23-01-07-91 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance Paint: All Technical Service Bulletins Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 130194 > May > 94 > Bumper Fascia - White/Stained Appearance > Page 9218 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 239794 > Dec > 94 > Paint Anti Chip Film/Front Fender Cap Repair Paint: All Technical Service Bulletins Paint Anti Chip Film/Front Fender Cap - Repair NO: 23-97-94 GROUP: Body DATE: Dec. 16, 1994 SUBJECT: Paint Anti-Chip Film and Front Fender Cap Repair Procedure MODELS: 1995 (PL) Neon DISCUSSION: As a running change, vehicles have been built with paint anti-chip film on several areas of the rocker panels. Also, vehicles may be equipped with front fender end caps. The following is a repair procedure for these items. PARTS REQUIRED: AR 4783115 Left or Right Front Rocker Panel Anti-Chip Film AR 4797292 Lower Rocker Panel "Darts" Anti-Chip Film (Pkg. 6) AR 4783116 Right Front Fender End Cap AR 4783117 Left Front Fender End Cap AR 6035204 Retaining Screw (Fender End Cap) AR 6032031 U-Nut (Fender End Cap) REPAIR PROCEDURE: This bulletin involves replacing damaged paint anti-chip film and/or front fender end caps. 1. Locate the paint anti-chip film to be replaced on the rocker panel (See Illustration). 2. Starting at one corner and using a heat gun, apply heat and slowly peel back the paint anti-chip film. Remove any residual adhesive using a commercial remover such as 3M adhesive remover # 08908 or equivalent. Wipe off the panel with a soft cloth saturated with a cleaner such as 3M adhesive cleaner # 08984 or equivalent. NOTE: APPLICATION OF PAINT ANTI-CHIP FILM SHOULD BE DONE WHEN THE AIR AND SURFACE TEMPERATURES ARE BETWEEN 70~ AND 90~ F. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 239794 > Dec > 94 > Paint Anti Chip Film/Front Fender Cap Repair > Page 9224 3. Remove the backing from the paint anti-chip film. Spray the film and/or the application area with a 50.-50 solution of isopropyl alcohol and water. 4. When applying the rocker panel film, align the top of the film approximately 1/16 In. (3 mm) below the break line in the rocker panel and 1/16 In. (3 mm) from the fender break line. When applying the "dart" film, place the middle of the film over the rear indentation (See Illustration). 5. When replacing the fender caps, use the lower two holes in the front fender. The two u-nuts, P/N 6032031, are installed on the fender and the inner fender liner/splash shield is between the fender cap and fender. Attach in place with two screws, P/N 6035204. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Cap, Wheel Opening, Fender, Replace Right/Left 23-02-59-90/91 0.2 Hrs. Film, Anti-Chip, Replace, Right or Left 23-01-07-90 0.2 Hrs. Film, Anti-Chip ("Darts"), Replace All 23-01-07-91 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9225 Paint: By Symptom Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9226 TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9227 REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9228 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Technical Service Bulletin # 130194 Date: 940527 Bumper Fascia - White/Stained Appearance NO: 13-01-94 GROUP: Frame & Bumpers DATE: May 27, 1994 SUBJECT: White Fascia Appearance MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO WHITE HIGHLINE VEHICLES IDENTIFIED WITH A 4 IN THE SIXTH DIGIT OF THE VIN NUMBER, BUILT PRIOR TO APRIL 22, 1994, (MDH 04-22-XX), EQUIPPED WITH WHITE GRAINED BUMPER FASCIAS. SYMPTOM/CONDITION: White front and/or rear bumper fascia is permanently stained or discolored by road film. Attempts to clean with detergents or chemicals are not effective. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9229 Inspect both front and rear fascias by examining the inside lower right side (wing) for trim number MH84 (Front) or MH85 (Rear) molded into the fascia (See Illustration). NOTE: ONLY BUMPER FASCIAS THAT DO NOT HAVE TRIM CODES MH84 OR MH85 ARE TO BE REPLACED FOR A DISCOLORATION CONDITION. PARTS REQUIRED: 1 MJ66PW7 Front Fascia, White Grained (Mold-In-Color) 1 MJ67PW7 Rear Fascia, White Grained (Mold-In-Color) REPAIR PROCEDURE: This bulletin involves replacing both white front and rear bumper fascia assemblies with revised parts made from a new material. The revised parts will not color match the old parts and initially, must be replaced in pairs. Replace the affected bumper fascia assemblies as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025, Page 13-1 & 13-2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-20-01-93 1.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Remove sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. 2. Slide sunshade (11) to full forward position. 3. Disengage slide blocks on one side of sunshade from sunshade guide (6). 4. Lift and pull sunshade out of opposite sunshade guide. INSTALLATION 1. Place sunshade with cloth side down and install one side's slide blocks into the track on the sunshade guide (6). 2. Slide the other side's slide blocks to fully inward position and insert them into the sunshade guide (6). 3. Verify that all four slide blocks are fully engaged in the sunshade guide (6). 4. Slide sunshade (11) fully rearward. 5. Install sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Remove sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. 2. Cycle the sunroof mechanism to the full forward position. CAUTION: Do not remove sunroof drive motor unless sunroof mechanism is in the full forward position. 3. Remove sunroof drive motor (10). Refer to procedure found in Sunroof Drive Motor/Service and Repair. 4. Remove front locator (7 or 8) for appropriate sunroof cable. 5. Disengage sunroof cable from sunroof mechanism (9). 6. Pull sunroof cable from drive tube (2 or 3). INSTALLATION 1. Push sunroof cable through drive tube (2 or 3). 2. Engage sunroof cable into sunroof mechanism (9). 3. Install front locator (7 or 8) over sunroof cable. Moving the sunroof mechanism rearward slightly will ease locator installation. 4. Move sunroof to full forward position. 5. Install sunroof drive motor (10). 6. Install sunroof glass panel (5). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. CAUTION: Do not cycle the sunroof drive motor prior to installation. The drive motor is shipped in the closed position. The sunroof vent position is programmed into the drive motor and is dependent upon the drive motor closed position. If the drive motor and the sunroof mechanism are not both in the closed position, the sunroof vent height will not be correct. REMOVAL 1. Remove headlining until the sunroof drive motor (10) can be accessed. 2. If the drive motor is to be reused, cycle the sunroof to the full forward position. 3. Disconnect wire harness connector from motor. 4. Remove the three screws attaching drive motor to sunroof module bracket. 5. Separate drive motor (10) from bracket. INSTALLATION 1. With the aid of a helper, hold the sunroof glass panel in the closed position and engage the drive motor (10) into the sunroof drive cables. 2. Install screws holding drive motor to bracket. 3. Connect wire harness to drive motor. 4. Install headlining. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. SUNROOF GUIDE AND MECHANISM ASSEMBLY Removal 1. Remove sunroof glass panel (4). Refer to procedure in Sunroof/Service and Repair. 2. Remove front locator (7 or 8). 3. Disengage cable from mechanism (9). 4. Remove screws holding sunroof guide (5) and mechanism (9) assembly to sunroof module. 5. Lift assembly from module. 6. Rotate assembly to disengage wind deflector (13) from assembly Installation 1. Engage wind deflector (13) into guide (5) and mechanism (9) assembly 2. Position assembly onto module and install screws holding assembly to sunroof module. 3. Engage drive cable to mechanism. 4. Install front locator (7 or 8). It may ease installation to move sunroof mechanism slightly rearward. 5. Install sunroof glass panel. Refer to procedure found in Sunroof/Service and Repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Open sunroof to full open position. 2. Pull one end of wind deflector flap out of the wind deflector beam (13). 3. Release corner piece locking tab and separate corner piece from wind deflector beam. 4. Rotate corner piece outboard to release tab from roof flange. 5. Rotate corner piece to a vertical position and pull it up through hole in guide (5). 6. Repeat for other corner piece. INSTALLATION 1. Hold corner piece vertically and push tab down through hole in guide (5). 2. Rotate corner piece inward and place tab under roof flange. 3. Connect corner piece to wind deflector beam (13). 4. Install wind deflector flap into wind deflector beam. 5. Repeat for other corner piece. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 9252 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 9253 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 9254 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 9255 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 9256 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose Seat Back: Customer Interest Seat Back Release Knob - Comes Loose NO: 23-67-95 GROUP: Body DATE: Nov. 3, 1995 SUBJECT: Seat Back Release Knob Comes Loose MODELS: 1995-1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 2 DOOR VEHICLES BUILT PRIOR TO 10-12-95 (MDH 10-12-XX). SYMPTOM/CONDITION: Plastic release knob falls off or housing may be cracked on seat back release. Knob may pull off when seat back release is being used or may be kicked off on entry/exit of rear seats. PARTS REQUIRED: 2 4773524 Knob and Housing, Inertia Release 1 4467709 Bond All Gel, Mopar REPAIR PROCEDURE: This bulletin involves the replacement of the inertia release knob and housing with revised parts. 1. If knob and housing are still attached to the lever, remove knob and housing by pulling straight out. The knob and housing should come loose by hand. 2. Apply the Mopar Bond All Gel (P/N 4467709) around the tip of the lever. Insure that the small pin on lever is covered with the bonding agent. Figure 1 3. Install the new knob and housing (P/N 4773524) immediately after applying the bond. Allow the repair to cure for one hour before use. 4. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose > Page 9265 Labor Operation No: 23-42-20-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 238794 > Nov > 94 > Front Seat Back - Squeaking Noise Seat Back: Customer Interest Front Seat Back - Squeaking Noise NO.: 23-87-94 GROUP: Body DATE: Nov. 25, 1994 SUBJECT: Front Seat Back Squeak MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Squeaking noise from the front seat back(s) when the occupant leans rearward in the seat. DIAGNOSIS: While sitting in the affected seat, lean rearward putting pressure on the upper portion of the seat back. If a squeaking noise is heard on the inboard lower portion of the seat back, proceed with the repair procedure. PARTS REQUIRED: AR 4778087 Pivot Bolt AR 6101283 U-Nut REPAIR PROCEDURE: This bulletin involves replacing the pivot bolt and U-nut on the affected seat(s). 1. Slide the affected seat to its furthest rearward position. NOTE: IF THE VEHICLE IS EQUIPPED WITH THE OPTIONAL CONSOLE WITH ARMREST, THE FOUR SCREWS INSIDE THE CONSOLE BIN MUST BE REMOVED AND THE CONSOLE MOVED AWAY FROM THE SEAT TO GAIN ACCESS TO THE PIVOT BOLT. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 238794 > Nov > 94 > Front Seat Back - Squeaking Noise > Page 9270 2. Remove the pivot bolt and the U-nut from the seat back frame (See Illustration). 3. Install new U-nut, P/N 6101283, on the seat back frame and new pivot bolt, P/N 4778087. NOTE: THE NEW PIVOT BOLT MUST BE TORQUED TO 115 +/- 9 IN.LBS. (13 +/- 1 N-M). ANY TORQUE GREATER THAN THESE SPECIFICATIONS MAY CAUSE THE U-NUT TO CRACK, LEADING TO THE ORIGINAL NOISE COMPLAINT. 3. Install the four screws inside the console bin, if removed for access in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-95 (Both Front Seats) 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose Seat Back: All Technical Service Bulletins Seat Back Release Knob - Comes Loose NO: 23-67-95 GROUP: Body DATE: Nov. 3, 1995 SUBJECT: Seat Back Release Knob Comes Loose MODELS: 1995-1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 2 DOOR VEHICLES BUILT PRIOR TO 10-12-95 (MDH 10-12-XX). SYMPTOM/CONDITION: Plastic release knob falls off or housing may be cracked on seat back release. Knob may pull off when seat back release is being used or may be kicked off on entry/exit of rear seats. PARTS REQUIRED: 2 4773524 Knob and Housing, Inertia Release 1 4467709 Bond All Gel, Mopar REPAIR PROCEDURE: This bulletin involves the replacement of the inertia release knob and housing with revised parts. 1. If knob and housing are still attached to the lever, remove knob and housing by pulling straight out. The knob and housing should come loose by hand. 2. Apply the Mopar Bond All Gel (P/N 4467709) around the tip of the lever. Insure that the small pin on lever is covered with the bonding agent. Figure 1 3. Install the new knob and housing (P/N 4773524) immediately after applying the bond. Allow the repair to cure for one hour before use. 4. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose > Page 9276 Labor Operation No: 23-42-20-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 238794 > Nov > 94 > Front Seat Back - Squeaking Noise Seat Back: All Technical Service Bulletins Front Seat Back - Squeaking Noise NO.: 23-87-94 GROUP: Body DATE: Nov. 25, 1994 SUBJECT: Front Seat Back Squeak MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Squeaking noise from the front seat back(s) when the occupant leans rearward in the seat. DIAGNOSIS: While sitting in the affected seat, lean rearward putting pressure on the upper portion of the seat back. If a squeaking noise is heard on the inboard lower portion of the seat back, proceed with the repair procedure. PARTS REQUIRED: AR 4778087 Pivot Bolt AR 6101283 U-Nut REPAIR PROCEDURE: This bulletin involves replacing the pivot bolt and U-nut on the affected seat(s). 1. Slide the affected seat to its furthest rearward position. NOTE: IF THE VEHICLE IS EQUIPPED WITH THE OPTIONAL CONSOLE WITH ARMREST, THE FOUR SCREWS INSIDE THE CONSOLE BIN MUST BE REMOVED AND THE CONSOLE MOVED AWAY FROM THE SEAT TO GAIN ACCESS TO THE PIVOT BOLT. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 238794 > Nov > 94 > Front Seat Back - Squeaking Noise > Page 9281 2. Remove the pivot bolt and the U-nut from the seat back frame (See Illustration). 3. Install new U-nut, P/N 6101283, on the seat back frame and new pivot bolt, P/N 4778087. NOTE: THE NEW PIVOT BOLT MUST BE TORQUED TO 115 +/- 9 IN.LBS. (13 +/- 1 N-M). ANY TORQUE GREATER THAN THESE SPECIFICATIONS MAY CAUSE THE U-NUT TO CRACK, LEADING TO THE ORIGINAL NOISE COMPLAINT. 3. Install the four screws inside the console bin, if removed for access in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-95 (Both Front Seats) 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > Competition Package Front Fascia - Information Air Dam: Technical Service Bulletins Competition Package Front Fascia - Information NO: 23-22-98 GROUP: Body DATE: Jun. 12, 1998 SUBJECT: Competition Package (Sales Code ACR) Front Fascia Information MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE (SALES CODE ACR) ONLY. DISCUSSION: Neon's built with the corn petition package (sales code ACR) are built with the same front fascia as a Sport, Expresso and RT models. The sport model front fascia includes holes for fog lamps. However on the competition package the fog lamps are not installed to allow for additional air flow during racing. If a replacement is necessary to a front fascia on a vehicle equipped with the competition package, it is important that the correct fascia with the fog lamp openings be installed. If a customer requests that fog lamps be added at their expense, they should be advised that if the vehicle is modified from original equipment it may then be illegal for some competition situations. The addition of fog lamps is not a warrantable issue. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise Cowl: Customer Interest A/C, Heater - Debris From Vents/Noise NO: 24-02-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Leaves/Debris in Heater-A/C System MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: ^ Debris comes out of the air outlets (applies to heater only equipped vehicles). ^ Noise at heater-A/C blower motor wheel due to leaves/debris in wheel. PARTS REQUIRED: 1 NPN Hardware Cloth (3" x 24" x 1/4"), Zinc Plated or Corrosion Resistant Coating) 3 6032723 Screws AR 4467708 Mopar Silicone Glass Sealer AR 4655021 Windshield Cowl Screen (for vehicles built prior to Jun. 6, 1994, MDH 06-06-XX). REPAIR PROCEDURE: This bulletin involves installing a fabricated screen over the cowl plenum air inlet openings on all vehicles, and on some vehicles cleaning air outlets and/or installing a revised windshield cowl screen. 1. For vehicles equipped with A/C, proceed to step 5. For heater only equipped vehicles, remove all upper panel air outlets by pivoting them downward with adequate force. Remove any debris/leaves from the outlet louvers. 2. Check the defroster outlet for any debris. If debris is evident, remove the instrument panel top cover as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page SE-7 and remove the debris. 3. Check the heater duct openings and remove any debris. With all outlets removed, turn blower to high and move the temperature control back and forth from cold to hot while cycling through all air distribution modes to blow out any debris in the duct system. 4. Install the instrument panel top cover, if removed. Install the air outlets. The outlets can only be installed one way, with the large diameter hinge on the left side. If noise was heard from the blower motor wheel, proceed to the next step, otherwise go to step 8. 5. Remove the blower motor and wheel assembly as outlined in the Service Manual, Pages 24-11 through 24-12. Remove any debris/leaves from the blower wheel and in the heater-A/C housing. 6. Remove any debris from the A/C condensate drain tube. 7. Install the blower motor and wheel assembly back into the heater-A/C housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 9296 8. Cut a section of hardware cloth as indicated (Figure 1). Cut the wire harness opening in an "X" pattern and fold inward (Figure 2). 9. Remove the wiper arm/blade assemblies. 10. Open the hood and remove the rear hood seal and windshield cowl screen. 11. Remove the blower motor resistor block, with wiring attached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 9297 12. Align the pre-cut hardware cloth over the air inlet openings (Figure 3). 13. Carefully slide the wiring harness up through the slit in the hardware cloth to the pre-cut opening. 14. Install the resistor block over the screen. Make sure the screen does not come in contact with the elements in the resistor block (Figure 2). 15. Install three screws, P/N 6032723, to secure the screen to the cowl plenum. 16. Apply Mopar Silicone Glass Sealer, P/N 4467708, around the outside edge of the screen to eliminate any potential for buzz, squeaks or rattles. NOTE: VEHICLES BUILT PRIOR TO JUN. 6, 1994 (MDH 06-06-XX) REQUIRE A NEW WINDSHIELD COWL SCREEN, P/N 4655021. 17. Install the windshield cowl screen and hood seal. 18. Install windshield wiper arm/blade assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Screen Cowl Install. Remove Debris from Heater Housing. A/C Equipped Vehicles 23-43-68-90...... .............................................................................................................................................................. ......0.4 Hrs. Screen Cowl Install. Remove Debris From Outlets and Heater Housing. Heater Only Equipped Vehicles 23-43-68-91........................................................................................................................... ...............................................0.6 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor Cowl: Customer Interest A Pillar - Water Leaks To Interior Floor NO: 23-48-94 GROUP: Body EFFECTIVE DATE: Jul. 15, 1994 SUBJECT: Water Leak In Passenger Compartment Under Instrument Panel MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Water leak from under instrument panel onto front floor area. Water may also be noticed in the glove box. Sloshing noise may be heard from instrument panel on turns. Water may leak on passenger floor area on left hand turn. DIAGNOSIS: 1. Remove instrument panel top cover and cluster bezel assembly by lifting up on the bottom outer areas of the cluster bezel and along the rearward edge to disengage the clips. Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel. 2. Remove both right and left A-Pillar trim moldings by pulling outward on the molding to disengage clips. 3. Run water on the windshield starting at the bottom and working up around the sides and around the top of the glass. Inspect for water dripping or running down the A-Pillars or front part of the windshield through the urethane bead. If a windshield water leak is found, repair as necessary before proceeding to the repair procedure. PARTS REQUIRED: AR 4318088 Butyl Rubber Sealer (Or Equivalent) AR 4467708 Silicone Windshield & Glass Sealer (Or Equivalent) AR 4655021 Cowl Screen Assembly (With Lip Seal) AR 4783100 Cowl Drain Tube AR 4655604 Cowl Top Patch REPAIR PROCEDURE: This bulletin involves sealing the cowl plenum, installing a cowl screen, and a cowl plenum drain tube. 1. On the inside of the vehicle, on the left top corner of the dash, fold back the cowl top silencer pad and temporarily retain it under the VIN plate pad on the instrument panel. Fold back the cowl top patch to gain access to the dash panel access hole. Refer to Figures 1 and 2. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9302 2. Look through the access hole in the cowl top and inspect for any water remaining in the cowl plenum. Remove any water that is present by using a vacuum through the access hole. Refer to Figure 1. 3. Remove the wiper arm assemblies. 4. Open the hood and remove the cowl-to-hood seal and the cowl screen assembly. 5. Disconnect the Wiper motor electrical connector and the three bolts holding the wiper assembly then remove the wiper motor assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9303 6. Apply Butyl Rubber Sealer P/N 4318088 (Or Equivalent) to the following areas of the cowl plenum. Refer to Figure 2, 3 and 4. A. Horizontal & vertical seams in the cowl plenum. B. Upper corner of the cowl plenum to cowl top extension (Right and Left sides). C. Bottom corner of A-Pillar transition (Right and Left sides). D. Horizontal and vertical seams under hood hinge attachment area (Right and Left sides.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9304 7. Force Silicone Windshield & Glass Sealer, P/N 4467708 (Or Equivalent), beneath the windshield edge to seal possible sheet metal leak covered by glass. Refer to Figure 4. 8. Install the wiper motor assembly. 9. Install a new Cowl Screen Assembly, P/N 4655021. 10. Install the wiper arm assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9305 11. Ensure drain tube is properly installed (Fig 5). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise Cowl: All Technical Service Bulletins A/C, Heater - Debris From Vents/Noise NO: 24-02-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Leaves/Debris in Heater-A/C System MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: ^ Debris comes out of the air outlets (applies to heater only equipped vehicles). ^ Noise at heater-A/C blower motor wheel due to leaves/debris in wheel. PARTS REQUIRED: 1 NPN Hardware Cloth (3" x 24" x 1/4"), Zinc Plated or Corrosion Resistant Coating) 3 6032723 Screws AR 4467708 Mopar Silicone Glass Sealer AR 4655021 Windshield Cowl Screen (for vehicles built prior to Jun. 6, 1994, MDH 06-06-XX). REPAIR PROCEDURE: This bulletin involves installing a fabricated screen over the cowl plenum air inlet openings on all vehicles, and on some vehicles cleaning air outlets and/or installing a revised windshield cowl screen. 1. For vehicles equipped with A/C, proceed to step 5. For heater only equipped vehicles, remove all upper panel air outlets by pivoting them downward with adequate force. Remove any debris/leaves from the outlet louvers. 2. Check the defroster outlet for any debris. If debris is evident, remove the instrument panel top cover as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page SE-7 and remove the debris. 3. Check the heater duct openings and remove any debris. With all outlets removed, turn blower to high and move the temperature control back and forth from cold to hot while cycling through all air distribution modes to blow out any debris in the duct system. 4. Install the instrument panel top cover, if removed. Install the air outlets. The outlets can only be installed one way, with the large diameter hinge on the left side. If noise was heard from the blower motor wheel, proceed to the next step, otherwise go to step 8. 5. Remove the blower motor and wheel assembly as outlined in the Service Manual, Pages 24-11 through 24-12. Remove any debris/leaves from the blower wheel and in the heater-A/C housing. 6. Remove any debris from the A/C condensate drain tube. 7. Install the blower motor and wheel assembly back into the heater-A/C housing. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 9311 8. Cut a section of hardware cloth as indicated (Figure 1). Cut the wire harness opening in an "X" pattern and fold inward (Figure 2). 9. Remove the wiper arm/blade assemblies. 10. Open the hood and remove the rear hood seal and windshield cowl screen. 11. Remove the blower motor resistor block, with wiring attached. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 240295 > Jan > 95 > A/C, Heater - Debris From Vents/Noise > Page 9312 12. Align the pre-cut hardware cloth over the air inlet openings (Figure 3). 13. Carefully slide the wiring harness up through the slit in the hardware cloth to the pre-cut opening. 14. Install the resistor block over the screen. Make sure the screen does not come in contact with the elements in the resistor block (Figure 2). 15. Install three screws, P/N 6032723, to secure the screen to the cowl plenum. 16. Apply Mopar Silicone Glass Sealer, P/N 4467708, around the outside edge of the screen to eliminate any potential for buzz, squeaks or rattles. NOTE: VEHICLES BUILT PRIOR TO JUN. 6, 1994 (MDH 06-06-XX) REQUIRE A NEW WINDSHIELD COWL SCREEN, P/N 4655021. 17. Install the windshield cowl screen and hood seal. 18. Install windshield wiper arm/blade assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Screen Cowl Install. Remove Debris from Heater Housing. A/C Equipped Vehicles 23-43-68-90...... .............................................................................................................................................................. ......0.4 Hrs. Screen Cowl Install. Remove Debris From Outlets and Heater Housing. Heater Only Equipped Vehicles 23-43-68-91........................................................................................................................... ...............................................0.6 Hrs. FAILURE CODE: PS - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor Cowl: All Technical Service Bulletins A Pillar - Water Leaks To Interior Floor NO: 23-48-94 GROUP: Body EFFECTIVE DATE: Jul. 15, 1994 SUBJECT: Water Leak In Passenger Compartment Under Instrument Panel MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Water leak from under instrument panel onto front floor area. Water may also be noticed in the glove box. Sloshing noise may be heard from instrument panel on turns. Water may leak on passenger floor area on left hand turn. DIAGNOSIS: 1. Remove instrument panel top cover and cluster bezel assembly by lifting up on the bottom outer areas of the cluster bezel and along the rearward edge to disengage the clips. Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel. 2. Remove both right and left A-Pillar trim moldings by pulling outward on the molding to disengage clips. 3. Run water on the windshield starting at the bottom and working up around the sides and around the top of the glass. Inspect for water dripping or running down the A-Pillars or front part of the windshield through the urethane bead. If a windshield water leak is found, repair as necessary before proceeding to the repair procedure. PARTS REQUIRED: AR 4318088 Butyl Rubber Sealer (Or Equivalent) AR 4467708 Silicone Windshield & Glass Sealer (Or Equivalent) AR 4655021 Cowl Screen Assembly (With Lip Seal) AR 4783100 Cowl Drain Tube AR 4655604 Cowl Top Patch REPAIR PROCEDURE: This bulletin involves sealing the cowl plenum, installing a cowl screen, and a cowl plenum drain tube. 1. On the inside of the vehicle, on the left top corner of the dash, fold back the cowl top silencer pad and temporarily retain it under the VIN plate pad on the instrument panel. Fold back the cowl top patch to gain access to the dash panel access hole. Refer to Figures 1 and 2. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9317 2. Look through the access hole in the cowl top and inspect for any water remaining in the cowl plenum. Remove any water that is present by using a vacuum through the access hole. Refer to Figure 1. 3. Remove the wiper arm assemblies. 4. Open the hood and remove the cowl-to-hood seal and the cowl screen assembly. 5. Disconnect the Wiper motor electrical connector and the three bolts holding the wiper assembly then remove the wiper motor assembly. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9318 6. Apply Butyl Rubber Sealer P/N 4318088 (Or Equivalent) to the following areas of the cowl plenum. Refer to Figure 2, 3 and 4. A. Horizontal & vertical seams in the cowl plenum. B. Upper corner of the cowl plenum to cowl top extension (Right and Left sides). C. Bottom corner of A-Pillar transition (Right and Left sides). D. Horizontal and vertical seams under hood hinge attachment area (Right and Left sides.) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9319 7. Force Silicone Windshield & Glass Sealer, P/N 4467708 (Or Equivalent), beneath the windshield edge to seal possible sheet metal leak covered by glass. Refer to Figure 4. 8. Install the wiper motor assembly. 9. Install a new Cowl Screen Assembly, P/N 4655021. 10. Install the wiper arm assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 234894 > Jul > 94 > A Pillar - Water Leaks To Interior Floor > Page 9320 11. Ensure drain tube is properly installed (Fig 5). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 9325 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 9326 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Page 9330 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Page 9331 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 9336 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Relay > Component Information > Description and Operation Cruise Control Relay: Description and Operation NAME OF CODE: Speed Control Power Relay Circuit WHEN MONITORED: With the ignition key ON, speed control switched ON, the SET button pressed and the brake pedal released. SET CONDITION: The speed control power supply circuit is either open or shorted to ground. THEORY OF OPERATION: The PCM monitors the voltage drop across all speed control solenoids and the power supply circuit. POSSIBLE CAUSES: - PCM misfire - Open or shorted power supply circuit - Failed dump solenoid (S/C servo) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Diagrams Fig. 13 Servo Harness Connector Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Diagrams > Page 9343 Speed Control Servo: Testing and Inspection 1. Turn ignition switch to ON position without starting engine. 2. Activate speed control ON switch. Fig. 13 Servo Harness Connector 3. Disconnect 4-way electrical connector and vacuum harness at servo. 4. Connect a jumper wire from pin 2 of the servo to pin 2 of the wire connector. 5. Ground pins 1, 3 and 4 in the servo connector 6. Connect a suitable hand held vacuum pump to the vacuum nipple of the servo and apply 10-15 inches of vacuum. 7. Ensure throttle cable pulls in and holds as long as long as vacuum pump is connected. After one minute, ensure cable is still holding. If cable does not hold, replace servo. 8. Disconnect pin 3 from ground. Cable should return to rest position. If cable does not return, replace servo. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Diagrams > Page 9344 Speed Control Servo: Service and Repair 1. Disconnect battery cables, then remove battery thermoguard, battery hold down and battery. 2. Remove power distribution center from back of battery tray. 3. Disconnect speed control cable from throttle body. 4. Remove screw holding support strut to front of battery tray. 5. Remove top battery tray fasteners. 6. Slide tray up and disconnect speed control servo wiring and vacuum harness from servo. 7. Remove attaching nuts and then speed control assembly from bottom of battery tray. 8. Reverse procedure to install ensuring servo wiring connector points toward the left front corner of vehicle when battery tray is installed. Torque nuts to 60 inch lbs. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High Cruise Control Switch: Description and Operation Speed Control Switch Always High NAME OF CODE: Speed Control Switch Always High WHEN MONITORED: With the ignition key ON. SET CONDITION: An open condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. POSSIBLE CAUSES: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High > Page 9349 Cruise Control Switch: Description and Operation Speed Control Switch Always Low NAME OF CODE: Speed Control Switch Always Low WHEN MONITORED: With the ignition key ON. SET CONDITION: A shorted condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is below 0.7 volts for more than 2 minutes. POSSIBLE CAUSES: - Mux switch circuit shorted to ground - Switch failure - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 9350 Cruise Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 9351 Cruise Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation NAME OF CODE: Speed Control Solenoid Circuits WHEN MONITORED: With the ignition key ON, speed control switched ON, and the SET button pressed. SET CONDITION: When the powertrain control module (PCM) actuates the vacuum and vent solenoids but they do not respond. THEORY OF OPERATION: When the "Set" switch is pressed, the vehicle must be moving forward at a speed between 35 - 85 MPH, with the transmission gear selector in other than park or neutral. The PCM locks in a set speed. Then the PCM energizes the vacuum solenoid to open the throttle and actuates the vent solenoid to close the throttle. These actuations are dependent on power supplied to the servo from the speed control relay through the brake switch. The system is deactivated by pressing the brake, turning the on/off switch OFF, or vehicle speed falling below the minimum. Reactivation can be done by repeating the previous steps or pressing resume with the vehicle speed between 35 - 85 MPH. POSSIBLE CAUSES: - Solenoid control circuit open or shorted - Vacuum or vent solenoid shorted or open - Open or shorted speed control power supply circuit - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Relay > Component Information > Description and Operation Cruise Control Relay: Description and Operation NAME OF CODE: Speed Control Power Relay Circuit WHEN MONITORED: With the ignition key ON, speed control switched ON, the SET button pressed and the brake pedal released. SET CONDITION: The speed control power supply circuit is either open or shorted to ground. THEORY OF OPERATION: The PCM monitors the voltage drop across all speed control solenoids and the power supply circuit. POSSIBLE CAUSES: - PCM misfire - Open or shorted power supply circuit - Failed dump solenoid (S/C servo) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 9363 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High Cruise Control Switch: Description and Operation Speed Control Switch Always High NAME OF CODE: Speed Control Switch Always High WHEN MONITORED: With the ignition key ON. SET CONDITION: An open condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. POSSIBLE CAUSES: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch Always High > Page 9368 Cruise Control Switch: Description and Operation Speed Control Switch Always Low NAME OF CODE: Speed Control Switch Always Low WHEN MONITORED: With the ignition key ON. SET CONDITION: A shorted condition is detected in the speed control on/off switch circuit. THEORY OF OPERATION: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is below 0.7 volts for more than 2 minutes. POSSIBLE CAUSES: - Mux switch circuit shorted to ground - Switch failure - PCM failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 9369 Cruise Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 9370 Cruise Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Warning Lamp: > 050294 > Feb > 94 > ABS - Warning Lamp ON Anti-Lock Warning Lamp: Customer Interest ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Warning Lamp: > 050294 > Feb > 94 > ABS - Warning Lamp ON Anti-Lock Warning Lamp: All Technical Service Bulletins ABS - Warning Lamp ON NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994 SUBJECT: ABS Warning Lamp Illuminated MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX. SYMPTOM/CONDITION: Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems are found, proceed with the following repair procedure. PARTS REQUIRED: 1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part. 1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89. NOTE: THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEE ILLUSTRATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-10-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Anti-Lock Warning Lamp <--> [ABS Light] > Component Information > Technical Service Bulletins > Page 9385 Anti-Lock Warning Lamp: Description and Operation The Antilock Brake System (ABS) warning lamp located on the instrument cluster will turn on when the CAB detects a condition which results in a shutdown of the ABS function. The ABS warning lamp will turn on for approximately four-five seconds after the ignition key is switched to the ON position. During this time the CAB runs a system self test. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation Ammeter Gauge: Description and Operation This LED operates independently of the gauge indicator and monitors system voltage. The LED will alert the driver of the following three charging system potential malfunctions: 1. A discharging condition, caused by excessive electrical demand on charging system (engine at idle RPM). 2. A weak or defective battery with ignition switch in On position (before ignition switch is moved to Start position). 3. A weak or defective battery with minimum demand on charging system, while vehicle is being used in stop and go driving (intermittent LED illumination occurring). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation > Page 9389 Ammeter Gauge: Testing and Inspection Use tester tool No. C-3826, or equivalent, when diagnosing systems. Proceed with the following test only if the battery and charging system are functioning properly. Turn ignition switch to the On position and turn on headlights, windshield wipers and stoplights. This will cause excessive demand on charging system activating the LED immediately or within approximately one minute. If the LED does not light, there is a malfunction in the system. If LED lights, run engine at approximately 2000 RPM, LED should stop emitting light. If the LED continues to emit light there is a malfunction in the system. In all cases of system malfunctions, the complete gauge must be replaced. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Description Brake Warning Indicator: Description and Operation ABS Warning Lamp Description ANTI-LOCK WARNING LAMP The Anti-Lock Warning lamp is used to alert the driver of a problem in the ABS system. When the ABS controller recognizes a problem in the system, it grounds the G19 circuit, which illuminates the lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Description > Page 9394 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description BRAKE WARNING LAMP The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicle's braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self-check. There are two switches used in this system and they are wired in parallel. A parking brake switch, located on the parking brake mechanism, illuminates the lamp if the normally open switch is closed. This switch is case-grounded. The other switch used is the Brake Warning lamp switch. This switch is normally open. When the brake system pressure is below a predetermined level, the switch closes and completes a path to ground from the G9 circuit at the cluster, through the switch, then to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). For further information on the DRL refer to the Front Lighting System section. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 9395 Brake Warning Indicator: Testing and Inspection Normal Operation The brake warning lamp illuminates when parking brake is applied with ignition key turned ON. The same lamp will also illuminate should one of the two service brake systems fail when brake pedal is applied. TO TEST SYSTEM: 1. Turn the ignition switch to the start position. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - Broken or disconnected wire at the switch 2. Turn ignition switch to ON position and apply parking brake. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - Broken or disconnected wire at the switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation CHARGE INDICATOR LAMP The Charge Indicator lamp is used to alert the operator that the charging system voltage has fallen below the normal operating range. This circuit is controlled by the Powertrain Control Module (PCM). When the PCM determines a problem, it grounds the G12 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9410 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9411 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 Horn/Cigar Lighter System Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 9419 Cigarette Lighter: Description and Operation CIGAR LIGHTER The cigar lighter is powered by a 40 amp maxi fuse located in the Power Distribution Center (PDC). There is also a 15 amp fuse located in cavity 1 of the fuse block dedicated for the cigar lighter. When the operator depresses the lighter, the contacts inside of the lighter element close, and voltage flows through the heating element to ground. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 9420 Cigarette Lighter: Testing and Inspection ^ Check the 40 amp maxi fuse located in the Power Distribution Center (PDC). ^ Check the 15 amp fuse located in the fuse block. ^ Check for a good ground at the instrument panel left center support. ^ Check the cigar lighter element. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 9427 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9439 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9444 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 9450 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9455 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation SPEEDOMETER / ODOMETER The speedometer and odometer receive their information on the G7 circuit from the vehicle-speed sensor. This circuit also provides a signal to the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9459 Driver/Vehicle Information Display: Service and Repair 1. Disconnect battery ground cable. 2. Remove instrument panel top cover and cluster bezel. 3. Remove four screws attaching cluster housing to base panel. 4. Pull cluster rearward to disconnect from base panel. 5. Remove cluster assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation FUEL GAUGE The fuel-level gauge is connected to the fuel pump module on the G4 circuit. The fuel pump module contains the fuel pump and the variable resistor for the gauge. Grounding for the fuel gauge is provided on the Z2 circuit, which terminates at the left rear wheel house. The fuel gauge contains a pair of coils and an indicator needle. As current flows through the coils in the fuel gauge, it creates a magnetic field in the gauge. The magnetic field controls the position of the fuel gauge pointer. The fuel-level sensor contains a variable resistor. As the position of the float arm on the level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Fuel Gauge Is the Only Inoperative Gauge Test Fuel Gauge: Testing and Inspection Fuel Gauge Is the Only Inoperative Gauge Test If the sending unit wiring is OK, replace the gauge assembly If the condition persists, replace the cluster printed circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Fuel Gauge Is the Only Inoperative Gauge Test > Page 9465 Fuel Gauge: Testing and Inspection Fuel Gauge Indicates Empty With Too Much Fuel In Tank The fuel system has both the instrument cluster and powertrain control module (PCM) monitoring the fuel level sending unit. If the PCM senses fuel monitoring open circuit, the increased resistance will cause a false fuel gauge empty reading. Check for continuity between instrument cluster Pin J2-10 and Pin 13 of the powertrain control module. - If there is no continuity, repair as necessary. If there is continuity, refer to Fuel Gauge test. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Fuel Gauge Is the Only Inoperative Gauge Test > Page 9466 Fuel Gauge: Testing and Inspection Fuel Gauge Test 1. Disconnect fuel gauge sending unit. 2. Turn ignition switch ON. The fuel gauge should be at its lowest position. Turn ignition switch OFF. 3. Ground fuel gauge sending unit connector Pin 4. Turn ignition switch ON. The temperature gauge should be at its highest position. Turn ignition switch OFF then ON, after a sending unit signal change to eliminate the cluster electronic gauge dampening mechanism. a. If OK, check fuel gauge sending unit connector for proper connection. If connections are OK, refer to Fuel Level Sending Unit Diagnosis. b. If not OK, connect the sending unit. Remove the cluster and check for an open or short in the sending unit wiring. The sending unit will be less than 1,080 ohms and greater than 50 ohms depending upon fuel level. If the sending unit wiring is open or short circuited, repair as necessary Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Fuel Gauge Is the Only Inoperative Gauge Test > Page 9467 Fuel Gauge: Testing and Inspection Sending Unit Test 1. Sending units and wiring can be checked by grounding the connector leads, at the sending unit, in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Page 9468 Fuel Gauge: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: Customer Interest Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9482 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9498 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9499 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9500 Fuel Tank Sending Unit Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation Fuel Gauge Sender: Description and Operation Fuel Level Sensor Operation FUEL LEVEL SENSOR Circuit G4 connects the fuel-level sensor to the fuel gauge in the instrument cluster, and splices to the Powertrain Control Module (PCM). The fuel-level sensor is a variable resistor. Circuit G5 from the fuse block supplies voltage to the fuel gauge. The fuel-level sensor draws voltage from circuit G5 through the fuel gauge on circuit G4. Circuit Z2 provides the ground path for the fuel-level sensor. The grounding point for circuit Z2 is the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9503 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too High NAME OF CODE: Fuel Level Sending Unit Volts Too High WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes above a calculated value. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating a low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9504 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too Low NAME OF CODE: Fuel Level Sending Unit Volts Too Low WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes below 0.75 volt. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low speeds. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9505 Fuel Gauge Sender: Description and Operation Fuel Level Unit No Change Over Miles NAME OF CODE: Fuel Level Unit No Change Over Miles WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 does not change a calibrated amount over a calculated number of miles. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration Fuel Gauge Sender: Testing and Inspection Test For Sending Unit Opration Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9508 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9509 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Helpful Information Gas current flows through coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel-level sensor contains a variable resistor. As the position of the float arm on the fuel-level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. ^ Circuit G4 connects to cavity 13 of the Powertrain Control Module (PCM) connector. The PCM determines low fuel level from circuit G4. Refer to Group 14 for fuel system operation. ^ Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 10 of the PCM, and cavity 2 of the TPS connector. ^ The PCM provides a ground for the throttle position sensor signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 3 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9510 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Testing Fig. 6 Level Sensor Diagnosis OPERATION This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Refer to the electrical diagrams for circuit identification. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. PROCEDURE 1. Connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. 2. Move the float lever to the positions shown in the resistance chart. 3. Record the resistance at each point. - Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9511 Fuel Gauge Sender: Testing and Inspection Fuel Pump Module Helpful Information Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9512 Fuel Gauge Sender: Service and Repair Fig. 7 Fuel Pump/Level Sensor Electrical Connector REMOVAL 1. Remove fuel pump module. Refer to procedure. 2. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 8 Wire Terminal Locking Wedge 3. Pull off blue locking wedge. Fig. 9 Wire Terminal Locking Finger 4. Using a small screwdriver lift locking finger away from terminal and push terminal out 6f connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9513 Fig. 10 Removing Wires From Connector 5. Push level sensor signal and ground terminals out of the connector. Fig. 11 Loosening Level Sensor 6. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Fig. 12 Level Sensor Removal/Installation 7. Slide level sensor wires through opening fuel pump module. 8. Slide level sensor out of installation channel in module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9514 Fig. 13 Groove In Back Side Of Level Sensor INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. Fig. 14 Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation > Headlamp-on Chime Description Headlamp Reminder Indicator: Description and Operation Headlamp-on Chime Description HEADLAMP-ON CHIME The Headlamp-ON chime is used to indicate to the operator that the headlamps or parking lamps are ON when the driver's door is open. If the lamps are ON and the driver's door is opened, a ground path is completed from the G26 circuit at the cluster, through the headlamp switch, to the G16 circuit, and ending at the door ajar switch. The door ajar switch is case-grounded. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation > Headlamp-on Chime Description > Page 9519 Headlamp Reminder Indicator: Description and Operation High-Beam Indicator Description HIGH-BEAM INDICATOR The High-Beam Indicator lamp is used to indicate to the operator that the high-beam headlamps are ON. Power is supplied to the cluster on the L3 circuit for vehicles without Daytime Running Lamp (DRL), or the G34 circuit for vehicles with DRL. Ground is provided on the Z3 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 9526 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Connect DRB to diagnostic 16-way connector, located at right side of the steering column near the side cowl. 2. Turn the ignition key to ON position. Exit vehicle with DRB. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the DRB, read and record active diagnostic code(s). 5. Read and record any stored data. 6. Refer to the Diagnostic Charts, if any diagnostic code(s) are found in steps 4 and 5. 7. Erase stored data if there are no active diagnostic codes. if problems remain, diagnostic codes will not erase. 8. Turn the ignition key to OFF then ON and observe the instrument cluster airbag lamp. it should go on for 6 to 8 seconds, then go out; indicating system is functioning normally. NOTE: If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the Diagnostic Charts to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN SWITCH The Key-IN chime is used to indicate to the operator that the key is in the ignition with the driver's door open. If the key is in the ignition and the driver's door is open, a ground path is completed from the G26 circuit at the cluster, through the closed Key-IN switch, to the G16 circuit, and terminating at the door ajar switch, which is case-grounded. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation LOW-FUEL LAMP The Low-Fuel lamp receives its information from a circuit internal to the instrument cluster. When the fuel gauge reaches a pre-determined level, the Low-Fuel lamp is illuminated. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 9533 Low Fuel Lamp/Indicator: Testing and Inspection The low fuel warning lamp receives its signal from the fuel gauge drive circuit. Due to production variations, the point where the lamp illuminates, may vary from 1/16 to 3/16 position on the fuel gauge. There is a built in time delay before the lamp illuminates. This prevents the lamp from going on and off under various road conditions. 1. Verify that fuel gauge is operating properly. 2. Check low fuel warning lamp assembly. 3. If lamp still does not function under a low fuel condition replace printed circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CHECK ENGINE (MALFUNCTION INDICATOR LAMP) The Check Engine lamp (Malfunction Indicator lamp) illuminates when the ignition switch is in the ON position, and prior to starting the vehicle. The lamp turns off after the vehicle is started. If, while the vehicle is running, a problem is detected in the engine control system, the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Odometer - Service Procedure Odometer: Technical Service Bulletins Odometer - Service Procedure NO: 08-04-94 GROUP: Electrical DATE: Jan. 28, 1994 SUBJECT: Odometer Service Procedure MODELS: 1995 (PL) Neon DISCUSSION: In the event of an odometer failure, a new replacement odometer must be obtained from the nearest authorized Huntsville Service Center. Unlike other Chrysler Corporation vehicle odometer assemblies, the Neon has two instead of one. One assembly calculates miles, the other kilometers. Therefore, when ordering an odometer from the service center, you must specify either a MILES or KILOMETER replacement. The assembly is identified by an "Mi" or "KM" over the odometer window below the speedometer. "MI" will typically be on U.S. specification vehicles, and "KM" will be on Canadian or export vehicles. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 9541 Odometer: Description and Operation The vehicle is equipped with an electronically driven odometer assembly. A signal is sent from a transmission-mounted vehicle speed sensor to the speedometer/odometer circuitry through the wiring harness. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 9542 Odometer: Service and Repair Fig. 6 Odometer REMOVAL 1. Remove instrument panel top cover and cluster bezel. 2. Remove four screws attaching cluster to instrument panel. 3. Remove cluster. 4. Remove six screws attaching PC board cover to cluster. 5. Disconnect odometer connector from printed circuit board. 6. Remove six screws attaching lens, dial and gauge assembly to housing. The bottom screws attaching lens to housing can be accessed without removing foam pad. 7. Remove lens and dial and gauge assembly from housing. 8. Remove two screws holding odometer to dial and gauge assembly When setting dial/gauge and/or cluster assembly down, it must be face up or damage will occur to the gauge operation. INSTALLATION 1. For installation reverse above procedures. NOTE: Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation LOW OIL-PRESSURE LAMP The Low Oil-Pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit, which also powers the other warning lamps. When the oil pressure is low, the normally open oil pressure switch closes, completing a path to ground. The oil pressure switch is case-grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 9552 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Fig. 3 Oil Pressure Switch Normal Operation The low oil pressure warning lamp will illuminate when the ignition key is turned to the ON position without engine running. The lamp also illuminates should the engine oil pressure drop below a safe oil pressure level. Low Oil Pressure Warning Lamp Test 1. To test the system turn ignition key to the ON position. - If the lamp lights circuit operation is normal. - If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, go to step 2. 2. Pull connector loose from the switch and with a jumper wire ground connector to the engine. 3. With the ignition key turned to the ON position check the warning lamp. - If lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING INDICATOR The Fasten Seat Belt indicator is used with the warning chime to tell the operator to fasten the seat belt. The seat belt switch is located in the driver's side B-pillar that is normally open when the seat belt is buckled. If the seat belt is not buckled, the switch closes, and a ground path is completed from the G1O circuit to the Z1 circuit. This illuminates the lamp in the instrument cluster. Ground for the seat belt switch is terminated at the right rear wheel house. When the ignition switch is moved to the START position, the lamp illuminates. Logic internal to the instrument cluster determines the length of time the lamp remains illuminated. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9568 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9573 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9579 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9584 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: Customer Interest Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 082895 > Jul > 95 > Fuel System - Engine Loss of Power/Stall/Misfire Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Engine Loss of Power/Stall/Misfire NO: 08-28-95 GROUP: Electrical EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Run Out of Fuel with Gauge Reading 1/8 to 1/4 Full THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-42-94 REVISION A DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). DIAGNOSIS AND PARTS HAVE BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT IN BELVEDERE WITH A "1" IN THE FIRST DIGIT OF THE VIN # BUILT PRIOR TO MAY 26, 1995, (MDH 05-26-XX) AND ALL VEHICLES BUILT IN MEXICO WITH A "3" IN THE FIRST DIGIT OF THE VIN #. SYMPTOM/CONDITION: Loss of power and/or possible engine misfire. Vehicle may stall and will not restart. Check engine lamp may be illuminated. Fuel gauge is reading 1/8 to 1/4 full, but vehicle operates as if it is out of fuel. DIAGNOSIS: 1. Lack of fuel may be confirmed by using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) to check for the presence of Diagnostic Trouble Codes (DTC's). If DTC (Single/Multiple Cylinder Misfire) is present, continue with the following diagnostic procedure before proceeding with other diagnostics using the Mopar Diagnostic System or the DRB III along with the 1995 Neon Powertrain Diagnostics Manual. 2. Check for proper fuel pressure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-7 to 14-8. If the fuel pressure reading is less than 15 PSI, the vehicle may be out of fuel. 3. Remove the fuel filler cap. Perform the Fuel System Pressure Release procedure as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 14-11. Disconnect the negative cable from the battery. Raise the vehicle on a hoist. Remove rubber cap from drain tube located on the fuel pump assembly flange. Attach 5/16" hose to the drain tube and apply a vacuum from a Fuel Storage Tanker. If fuel is present, the problem is not with the fuel tank level unit or gauge and further diagnosis of the fuel delivery system will be necessary. If no fuel is present, follow the procedure to determine whether the fuel gauge or fuel tank level unit is defective, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 8E-3 through 8E-4. **Most likely, the fuel tank level unit conductor elements have deteriorated and are causing the incorrect reading.** Proceed with the following repair procedure. PARTS REQUIRED: 1 **4864020** Fuel Tank Level Unit REPAIR PROCEDURE: **This bulletin involves replacing the fuel tank level unit with a revised unit.** 1. Install new fuel tank level unit, PIN **4864020**, as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 14-5 to 14-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-30-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9598 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9601 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9602 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9603 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9604 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9605 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9606 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9607 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9608 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9609 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9610 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9611 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9612 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9613 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9614 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9615 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 9616 Fuel Tank Sending Unit Circuit Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation Fuel Gauge Sender: Description and Operation Fuel Level Sensor Operation FUEL LEVEL SENSOR Circuit G4 connects the fuel-level sensor to the fuel gauge in the instrument cluster, and splices to the Powertrain Control Module (PCM). The fuel-level sensor is a variable resistor. Circuit G5 from the fuse block supplies voltage to the fuel gauge. The fuel-level sensor draws voltage from circuit G5 through the fuel gauge on circuit G4. Circuit Z2 provides the ground path for the fuel-level sensor. The grounding point for circuit Z2 is the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9619 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too High NAME OF CODE: Fuel Level Sending Unit Volts Too High WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes above a calculated value. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating a low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9620 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit Voltage Too Low NAME OF CODE: Fuel Level Sending Unit Volts Too Low WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 goes below 0.75 volt. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low speeds. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Level Sensor Operation > Page 9621 Fuel Gauge Sender: Description and Operation Fuel Level Unit No Change Over Miles NAME OF CODE: Fuel Level Unit No Change Over Miles WHEN MONITORED: Ignition ON. SET CONDITION: The fuel level sensor signal circuit voltage at Powertrain Control Module (PCM) cavity 13 does not change a calibrated amount over a calculated number of miles. THEORY OF OPERATION: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. POSSIBLE CAUSES: - Open sensor signal circuit - Fuel level sending unit failure Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration Fuel Gauge Sender: Testing and Inspection Test For Sending Unit Opration Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9624 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9625 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Helpful Information Gas current flows through coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel-level sensor contains a variable resistor. As the position of the float arm on the fuel-level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. ^ Circuit G4 connects to cavity 13 of the Powertrain Control Module (PCM) connector. The PCM determines low fuel level from circuit G4. Refer to Group 14 for fuel system operation. ^ Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 10 of the PCM, and cavity 2 of the TPS connector. ^ The PCM provides a ground for the throttle position sensor signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 51 of the PCM connector, and splices to cavity 3 of the sensor connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9626 Fuel Gauge Sender: Testing and Inspection Fuel Level Sensor Testing Fig. 6 Level Sensor Diagnosis OPERATION This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. Refer to the electrical diagrams for circuit identification. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. PROCEDURE 1. Connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. 2. Move the float lever to the positions shown in the resistance chart. 3. Record the resistance at each point. - Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Test For Sending Unit Opration > Page 9627 Fuel Gauge Sender: Testing and Inspection Fuel Pump Module Helpful Information Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: ^ Upstream heated oxygen sensor ^ Downstream heated oxygen sensor ^ Battery temperature sensor ^ Camshaft position sensor ^ Crankshaft position sensor ^ Engine coolant temperature sensor ^ Manifold absolute pressure sensor ^ Knock sensor ^ Intake air temperature sensor ^ Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9628 Fuel Gauge Sender: Service and Repair Fig. 7 Fuel Pump/Level Sensor Electrical Connector REMOVAL 1. Remove fuel pump module. Refer to procedure. 2. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 8 Wire Terminal Locking Wedge 3. Pull off blue locking wedge. Fig. 9 Wire Terminal Locking Finger 4. Using a small screwdriver lift locking finger away from terminal and push terminal out 6f connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9629 Fig. 10 Removing Wires From Connector 5. Push level sensor signal and ground terminals out of the connector. Fig. 11 Loosening Level Sensor 6. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly. Fig. 12 Level Sensor Removal/Installation 7. Slide level sensor wires through opening fuel pump module. 8. Slide level sensor out of installation channel in module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 9630 Fig. 13 Groove In Back Side Of Level Sensor INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. Fig. 14 Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN SWITCH The Key-IN chime is used to indicate to the operator that the key is in the ignition with the driver's door open. If the key is in the ignition and the driver's door is open, a ground path is completed from the G26 circuit at the cluster, through the closed Key-IN switch, to the G16 circuit, and terminating at the door ajar switch, which is case-grounded. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Head: Customer Interest Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 9642 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 087794 > Dec > 94 > Speedometer - Inoperative Speedometer Head: All Technical Service Bulletins Speedometer - Inoperative NO: 08-77-94 GROUP: Electrical DATE: Dec. 30,1994 SUBJECT: Inoperative Speedometer MODELS: 1994 - 1995 (AS) Caravan/Voyager/Town & Country 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 31TH AUTOMATIC TRANSAXLE AND BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) OR TO THE A5231A568 MANUAL TRANSAXLE BUILT PRIOR TO NOV. 4, 1994 (MDH 11-04-XX). SYMPTOM/CONDITION: Inoperative speedometer due to loss of signal from Vehicle Speed Sensor (VSS). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/electrical systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If a "No Vehicle Speed Sensor(VSS) Signal" DTC is present and all other systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707386 Vehicle Speed Sensor 1 6501714 Attaching Screw - w/Lokpatch AR 4567880 Pinion Gear (Yellow) AR 4567881 Pinion Gear (Blue) AR 4567882 Pinion Gear (Black) AR 4567883 Pinion Gear (Red) AR 4318031 Lock N'Seal REPAIR PROCEDURE: This bulletin involves removing the Vehicle Speed Sensor (VSS), pinion gear and the attaching screw and replacing them with new parts. 1. Disconnect the vehicle speed sensor wire harness connector, remove sensor mounting screw, the vehicle speed sensor and the pinion gear. NOTE: THE MOUNTING SCREW SHOULD NOT BE REUSED. 2. Install a new vehicle speed sensor and pinion gear. INSTALL ONLY THE SAME COLOR PINION GEAR THAT WAS REMOVED IN STEP 1. Automatic Transaxle: 3. Install a new mounting screw, P/N 6501714. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1/2 TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. Manual Transaxle: A) Apply Lock N' Seal, P/N 4318031, to the threaded hole in the MTX extension. Care should be taken to avoid getting Lock N' Seal inside the case or in the oil. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 087794 > Dec > 94 > Speedometer - Inoperative > Page 9648 B) Apply one drop of Lock N' Seal to the new mounting screw, P/N 6501714. C) Install new mounting screw. IMPORTANT: TIGHTEN THE ATTACHING SCREW TO 60 IN. LBS. AND THEN BACK THE SCREW OFF 1 FULL TURN. FOLLOW THIS PROCEDURE ANY TIME A VEHICLE SPEED SENSOR IS INSTALLED. 4. Install the vehicle speed sensor wire harness connector. 5. Repeat the diagnostic procedure to confirm that the vehicle speed sensor is functioning properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-13-95.......................................................................................................................................... ................................0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Page 9649 Speedometer Head: Description and Operation The vehicle is equipped with electronically driven speedometer and odometer assemblies. A signal is sent from a transmission-mounted vehicle speed sensor to the speedometer circuitry through the wiring harness. The speedometer has two main parts: the indicator head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or housing is probably broken. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Page 9650 Speedometer Head: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The tachometer is connected to the Powertrain Control Module (PCM) on the G21 circuit. It uses solid-state circuitry to decode the ignition pulses received from the PCM. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 9654 Tachometer: Testing and Inspection Fig. 4 Cluster Wire Harness Connector 1. Remove cluster, refer to Cluster Removal. 2. Check for battery voltage at pin 6 of the J1 of the cluster wire harness connector. 3. With the ignition switch in the ON position, check for battery voltage at pin 5 of the J1 connector. 4. Check pin 8 of the J1 connector for continuity to ground. 5. Check for tachometer signal from the power- train control module by connecting an AC DIGITAL VOLTMETER to pin 7 of the J1 connector and ground. A reading of at least 1.0 volts should be present with the engine running. a. If voltage is within specification, go to step 7. b. If voltage is NOT within specification, go to step 6. Fig. 7 Powertrain Control Module Pin Location 6. If there is less than 1.0 volts at pin 7 of the J1 connector, check for continuity between pin 7 and pin 37 of the powertrain control module connector. Also, check the connector at the powertrain control module for damaged pins or terminal push outs. 7. If voltage is less than 1.0 volts at pin 7 of the J1 connector and there is continuity between pin 7 and pin 37 of the powertrain control module connector, replace the powertrain control module. 8. If all tests performed test good replace the dial and gauge assembly 9. If the tachometer continues to be inoperative, replace the print circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 9655 Tachometer: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAUGE The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM), and the other side for the instrument cluster. The sending unit is case grounded to the engine. The gauge uses two coils, and the current passing through the coils creates a magnetic field. Movement of the needle is determined by the amount of current passing through the coils to ground at the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test Temperature Gauge: Testing and Inspection Temperature Gauge Test Fig. 6 Engine Coolant Temperature Sensor 1. Disconnect temperature sending unit. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF. 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp go out, the cluster should chime for about eight seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, the high temperature chime sounds but the gauge shows cold. Replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Test > Page 9661 Temperature Gauge: Testing and Inspection Sending Unit Test 1. Sending units and wiring can be checked by grounding the connector leads, at the sending unit, in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Page 9662 Temperature Gauge: Service and Repair Fig. 3 Cluster Assembly CAUTION: Cluster MUST be stored in a face up position or damage will occur to the gauge operation. NOTE: Before disassembling the cluster check for a defective sending unit or wiring. CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Fig. 4 Printed Circuit Boards 3. Disconnect odometer connector and remove seven attaching printed circuit (PC) board and housing. 4. Carefully remove printed circuit board from the cluster. 5. For installation reverse above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to assure pins on gauges line up. GAUGE REMOVAL 1. Remove cluster, refer to Cluster Removal. 2. Remove six screws attaching PC board cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. 3. Disconnect odometer connector. 4. Remove six lens screws and remove lens. 5. Carefully pry out dial and gauge assembly. 6. For installation reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation Transmission Shift Position Indicator Lamp: Description and Operation PRNDL (TRANSMISSION RANGE INDICATOR) LAMP DESCRIPTION The PRNDL lamp receives power on the E2 circuit from the 4 amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2, which is HOT at all times, also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: Customer Interest M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: All Technical Service Bulletins M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode Housing Assembly HVAC: All Technical Service Bulletins A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 9686 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 9692 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 9693 Backup Lamp Switch: Description and Operation BACK-UP LAMP SWITCH On automatic transmissions, the back-up lamp switch is part of the PARK/NEUTRAL position switch. The back-up lamp switch does not connect to the Powertrain Control Module (PCM) on manual transaxle equipped vehicles. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 9694 Backup Lamp Switch: Testing and Inspection In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 Amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp <--> [Brake Lamp] > Component Information > Description and Operation > Stop Lamp Description Stop Lamp: Description and Operation Stop Lamp Description STOP LAMPS Circuit F32 in the Power Distribution Center (PDC) feeds the stop lamps. Circuit F32 connects to the stop lamp switch. A 15 amp fuse in the PDC protects circuit F32. When the operator depresses the brake pedal, the stop lamp switch closes, and connects circuit F32 to circuit L50. Circuit L50 connects to the multi-function switch and supplies current to the L62 and L63 circuits. Circuit L62 powers the right stop lamp. Circuit L63 powers the left stop lamp. Circuit L50 splices to power the CHMSL lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp <--> [Brake Lamp] > Component Information > Description and Operation > Stop Lamp Description > Page 9699 Stop Lamp: Description and Operation Stop Lamp Ground Circuit GROUND CIRCUIT Circuit Z1 provides a ground for the stop lamps, CHMSL lamp, and the stop lamp switch. The Z1 circuit has more than one grounding point, and supplies ground path for the tail lamps, parking lamps, head-lamps, side marker lamps, rear license plate lamp, back-up lamps, and turn signals. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp <--> [Brake Lamp] > Component Information > Description and Operation > Page 9700 Stop Lamp: Testing and Inspection ^ Check for blown fuses in circuit F32 (in PDC). ^ Check for continuity across the stop lamp switch when it is closed. ^ For rear lighting on the left side of the vehicle, the Z1 circuit grounding point is in the left rear wheel well. ^ For rear lighting on the right side of the vehicle, the Z1 circuit grounding point is in the right rear wheel well. ^ For the stop lamp switch, the Z1 circuit grounding point is in the left front inner fender shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 9705 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9706 Stop Lamp Switch: Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9707 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Description and Operation Ash Tray Lamp: Description and Operation ASH RECEIVER LAMP The ash receiver lamp receives power on the E2 circuit from the 4 amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2, which is HOT at all times, also powers the Transmission Range Indicator (PRNDL) lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the ash receiver lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the PRNDL lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Description and Operation Door Lamp: Description and Operation GENERAL INFORMATION The courtesy lamp system is powered at all times by the 10 amp micro fuse located in the Power Distribution Center (PDC). The M1 circuit feeds the courtesy lamps, which include the trunk lamp, underhood lamp, visor/vanity lamps, dome lamp, time delay relay, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Glove Box Lamp: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9723 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Glove Box Lamp: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9729 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 9735 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Coil Spring - Metallic Click Noise NO: 02-02-95 GROUP: Suspension DATE: Feb. 10, 1995 SUBJECT: Front Coil Spring Click MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO OCT. 3, 1994 (MDH 1O-03-XX). SYMPTOM/CONDITION: Customer complaint of a metallic click coming from either front strut assembly. The noise can occur when driving over bumpy road surfaces, but typically can be noticed over roads with medium to large bumps. The noise should be more detectable at speeds around 30 MPH. This noise should not be confused with a power steering system rattle which transmits through the steering column or front fender inner splash shield rattles. DIAGNOSIS: Inspect left and right front coil springs for signs of contact between the first and second coils from the top of the springs. It may be necessary to remove the front strut assembly to sufficiently inspect the coil spring. If contact is noted, proceed to the repair procedure. PARTS REQUIRED: AR 5273401 Front Coil Spring Assembly (with tag I.D. 401) AR 5273402 Front Coil Spring Assembly (with tag I.D. 402) AR 5273403 Front Coil Spring Assembly (with tag I.D. 403) AR 5273404 Front Coil Spring Assembly (with tag I.D. 404) AR 5273405 Front Coil Spring Assembly (with tag I.D. 405) AR 5273406 Front Coil Spring Assembly (with tag I.D. 406) AR 5273407 Front Coil Spring Assembly (with tag I.D. 407) AR 5273408 Front Coil Spring Assembly (with tag I.D. 408) AR 5273409 Front Coil Spring Assembly (with tag I.D. 409) AR 5273411 Front Coil Spring Assembly (with tag I.D. 411) AR 5273412 Front Coil Spring Assembly (with tag I.D. 412) AR 5273413 Front Coil Spring Assembly (with tag I.D. 413) AR 5273414 Front Coil Spring Assembly (with tag I.D. 414) AR 5273415 Front Coil Spring Assembly (with tag I.D. 415) AR 5273416 Front Coil Spring Assembly (with tag I.D. 416) AR 5273417 Front Coil Spring Assembly (with tag I.D. 417) NOTE: THE FRONT COIL SPRING CAN BE IDENTIFIED BY A TAPE LABEL I.D. TAG LOCATED APPROXIMATELY ON THE MIDDLE COIL. IT WILL HAVE THE LAST THREE DIGITS OF THE PART NUMBER NEEDED TO IDENTIFY THE CORRECT REPLACEMENT SPRING. THE NEW COIL SPRING CAN BE IDENTIFIED BY THE ADDITION OF A POLYURETHANE SLEEVE BETWEEN THE TOP TWO COILS. REPAIR PROCEDURE: This bulletin involves replacing one or both front coil springs. 1. Replace the affected front coil spring(s) as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 2-10 through 2-15, with the correct part number called out in the Parts Required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Spring, Front Coil, Inspect and Replace, One Side Labor Operation No: 02-27-01-98 ......................................................................................................................................... ................................ 0.6 Hrs. Spring, Front Coil, Inspect and Replace, Both Sides Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise > Page 9740 02-27-01-99 ......................................................................................................................................... ................................ 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 9746 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp: > 020295 > Feb > 95 > Front Coil Spring - Metallic Click Noise > Page 9751 02-27-01-99 ......................................................................................................................................... ................................ 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Page 9752 Glove Box Lamp: Description and Operation GLOVE BOX LAMP The glove box lamp receives power on the M1 circuit from the 10 amp fuse located in the Power Distribution Center (PDC). A switch, wired in series after the lamp, closes when the glove box door is opened, and completes a path to ground on the Z3 circuit. The Z3 circuit is spliced in with the ash receiver lamp, PRNDL lamp, and the time delay relay. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation DAYTIME RUNNING LAMP (DRL) MODULE - CANADIAN VEHICLES ONLY On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position, and the parking brake switch is open. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 amp maxi fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block that feeds circuit G5 through a 5 amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G5 connects to cavity 1 of the DRL module. Circuit G9 connects to cavity 3 of the DRL module. The G9 circuit splices to the brake warning switch, park brake switch, and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the Power Distribution Center feeds circuit L20. Circuit L20 connects to cavity 6 of the DRL module connector. A 40 amp maxi fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the lowbeams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit L4 originates at cavity 4 of the multi-function switch. The L4 circuit splices to cavity 10 of the DRL module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Description and Operation Dome Lamp: Description and Operation DOME LAMP The dome lamp receives power from the 10 amp micro fuse located in the Power Distribution Center (PDC) on the M1 circuit. This circuit is HOT at all times. The ground path for the lamp is provided in two different ways. One way is through the door ajar switches. Circuit M2 connects to all the door ajar switches from the dome lamp. The switches are case-grounded to the body. When a door is opened, the plunger in the switch closes, completing a path to ground. The second ground path is through the headlamp switch. Circuit M2 is spliced in with the door ajar switches. When the operator turns the headlamp switch to the dome lamp ON position, a ground path is provided through the switch on the Z1 circuit. This ground terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9771 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9776 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9782 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9787 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Fog Lamp <--> [Fog/Driving Lamp] > Component Information > Description and Operation > Fog Lamp Fog Lamp: Description and Operation Fog Lamp FOG LAMPS The fog lamps operate only when the headlamp switch is in the ON position, and the operator has selected low-beam operation. When the headlamps are in high-beam operation, the fog lamps will not operate. Circuit A3 from the Power Distribution Center (PDC) supplies current to a bus bar in the fuse block. Circuit F6l is one of four circuits that the bus bar feeds and is protected by a 10 amp fuse in cavity 4. Circuit F6l connects to the fog lamp switch. The fog lamp switch contains a relay that supplies current to the fog lamps. Circuit L4 from the multi- function switch supplies current to the coil side of the relay (only when the headlamps operate on low- beam). Circuit F6l supplies current to the contact side of the relay. During low-beam headlamp operation when the fog lamp switch contacts close, circuit F6l connects to circuit L39. Circuit L39 feeds the right and left fog lamps. Circuit L39 also feeds the green LED in the switch that illuminates during fog lamp operation. When the headlamp switch is in the PARK or ON position, circuit E1 from the headlamp switch supplies current for circuit E2. Circuit E2 contains a 4 amp fuse in cavity 12 of the fuse block, and powers the bulb in the fog lamp switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Fog Lamp <--> [Fog/Driving Lamp] > Component Information > Description and Operation > Fog Lamp > Page 9792 Fog Lamp: Description and Operation Ground Circuit GROUND CIRCUIT Although circuit Z1 provides the ground path for the fog lamps, the circuit has a different grounding point for each lamp. For the left fog lamp, the grounding point is on the left side of the radiator closure panel. For the right fog lamp, the grounding point is in the right fender side shield. Circuit Z3 supplies a ground path for the fog lamp switch. The grounding point for the headlamp switch is the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Fog Lamp <--> [Fog/Driving Lamp] > Component Information > Description and Operation > Page 9793 Fog Lamp: Testing and Inspection ^ Circuit Z1 also supplies a ground for the side marker lamps, turn signals, parking lamps, and headlamps. ^ Circuit A3 from the Power Distribution Center (PDC) supplies current to the headlamp switch for circuit L2. ^ Circuit F33 from the fuse block supplies current to the headlamp switch for circuit E1. Circuit A3 from the PDC supplies current to a bus bar in the fuse block that feeds the F33 circuit. Fuse 2, in the fuse block, protects the F33 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations TURN SIGNAL AND HAZARD WARNING The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). The combo-flasher controls the flashing of the hazard warning system and the turn signal system. An inoperative bulb or incomplete turn signal circuit will cause the flasher rate tio double. The combo-flasher is located on the fuse block. The combo-flasher is black in color for ease of indentification. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Hazard Flashers Description Hazard Warning Flasher: Description and Operation Hazard Flashers Description HAZARD FLASHERS Circuit L9 from the Power Distribution Center (PDC) supplies battery voltage for the hazard flashers. A 10 amp micro fuse in the PDC protects circuit L9. Circuit L9 connects to pin 6 of the multi-function switch. With the hazard flashers on, the multi-function switch connects circuits L9 and L55. Circuit L55 feeds the combination flasher unit. Circuit Z2 provides ground for the flasher unit. From the flasher unit, circuit L32 connects to cavity 3 of the multi-function switch. With the hazard flashers on, the multi-function switch connects circuit L32 to circuits L60, L61, L62, and L63. Circuit L60 supplies voltage to the right front turn signal/hazard lamp. The L60 circuit splices to the instrument cluster to power the right indicator lamp. Circuit L60 connects to cavity 6 of the multi-function switch connector. Circuit L61 supplies voltage to the left front turn signal/hazard lamp. The L61 circuit splices to the instrument cluster to power the left indicator lamp. Circuit L61 connects to cavity 10 of the multi-function switch connector. Circuit L62 supplies voltage to the right rear turn signal/hazard flasher/stop lamp. Circuit L62 connects to cavity 4 of the multi-function switch connector. Circuit L63 supplies voltage to the left rear turn signal/hazard/flasher/stop lamp. Circuit L63 connects to cavity 9 of the multi-function switch connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Hazard Flashers Description > Page 9800 Hazard Warning Flasher: Description and Operation Hazard Flashers Ground Circuit Description GROUND CIRCUITS Circuit Z3 provides ground for the instrument cluster indicator lamps. The termination point for circuit Z3 is the instrument panel left center support. Circuit Z1 provides ground for all turn signal/hazard lamps, although it has different grounding points for each circuit. Circuit Z2 provides the ground path for the combination flasher unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 9801 Hazard Warning Flasher: Testing and Inspection ^ For the left front turn signal/hazard flasher lamp, the Z1 circuit grounding point is the left side radiator closure panel. ^ For the right front turn signal/hazard flasher lamp, the Z1 circuit grounding point is in the right fender side shield. ^ For the left rear turn signal/hazard flasher/stop lamp, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear turn signal/hazard flasher/stop lamp, the Z1 circuit grounding point is in the right rear wheel well. ^ Circuit Z1 also supplies ground for the headlamps, parking lamps, rear license plate lamp, back-up lamps, and side marker lamps. ^ The grounding point for circuit Z2 is the instrument panel right center support. Circuit Z2 supplies ground for the combination flasher unit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 amp maxi fuse protects the A3 circuit. The headlamp switch has an internal 24 amp circuit breaker that connects circuit A3 to either the L2 or L20 circuit, depending on switch position. In the OFF and PARK positions, cavity 7 of the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the head-lamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 9807 Headlamp Switch: Description and Operation Headlamp Switch In ON Position HEADLAMP SWITCH IN ON POSITION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low-beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in the fuse block, and power the low-beam headlamps. Circuit L43 supplies current to the left headlamp. Circuit L44 supplies current to the right headlamp. The L43 and L44 circuits each have separate 10 amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high-beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high-beam operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 9808 Headlamp Switch: Testing and Inspection ^ Cavity 7 (circuit L20) of the headlamp switch connector is double-crimped to feed the Daytime Running Lamp (DRL) module. ^ Check for a blown fuse in cavity 17 for L43 and in cavity 18 for L44. ^ Check the 40 amp maxi fuse located in the Power Distribution Center (PDC). ^ The headlamp switch has a 24 amp internal circuit breaker. ^ For the left front parking lamp, turn signal, side marker lamp, and left headlamp, the Z1 circuit grounding point is on the left side of the radiator closure panel. ^ For the right front parking lamp, turn signal, side marker lamp, and right headlamp, the Z1 circuit grounding point is in the right fender side shield. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 9809 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Key Cylinder Lamp: > 084994 > Sep > 94 > Ignition Key Lamp - Lack of Illumination Key Cylinder Lamp: Customer Interest Ignition Key Lamp - Lack of Illumination NO: 08-49-94 GROUP: Electrical DATE: Sep. 16, 1994 SUBJECT: Ignition Key Lamp Illumination MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SALES CODE ADA (LIGHT GROUP), WHICH INCLUDES AN ILLUMINATED IGNITION KEY SWITCH WITH TIME DELAY. SYMPTOM/CONDITION: Lack of illumination of ignition key switch. PARTS REQUIRED: 1 4796657 Clip, With Shim REPAIR PROCEDURE: This bulletin involves increasing the clearance between the instrument panel and the steering column cover to allow more light to focus on the ignition key switch. 1. Remove the instrument panel top cover and cluster bezel and the right trim panel as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 8E-7. Disconnect the wiring connector to the rear window defogger and fog lamp switch located on the right trim panel, if vehicle is so equipped. 2. Remove 2 mm (approximately 1/16 in.) of material from the upper portion of the left instrument panel clip attachment hole (refer to illustration). 3. Remove the old clip on the right trim panel and install new clip P/N 4796657, on the trim panel with the clip portion facing upward. The new clip has additional material on the bottom surface that will force the panel upward when it is installed on the instrument panel. This will allow a minimum of 3 mm (approximately 1/8 in.) clearance between the right trim panel and steering column cover (refer to illustration). 4. Connect the wiring connector to the rear window defogger and fog lamp switch located on the right trim panel, if disconnected in Step 1. Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Key Cylinder Lamp: > 084994 > Sep > 94 > Ignition Key Lamp - Lack of Illumination > Page 9822 the right trim panel and instrument panel top as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 8E-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-50-50-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Key Cylinder Lamp: > 084994 > Sep > 94 > Ignition Key Lamp - Lack of Illumination Key Cylinder Lamp: All Technical Service Bulletins Ignition Key Lamp - Lack of Illumination NO: 08-49-94 GROUP: Electrical DATE: Sep. 16, 1994 SUBJECT: Ignition Key Lamp Illumination MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SALES CODE ADA (LIGHT GROUP), WHICH INCLUDES AN ILLUMINATED IGNITION KEY SWITCH WITH TIME DELAY. SYMPTOM/CONDITION: Lack of illumination of ignition key switch. PARTS REQUIRED: 1 4796657 Clip, With Shim REPAIR PROCEDURE: This bulletin involves increasing the clearance between the instrument panel and the steering column cover to allow more light to focus on the ignition key switch. 1. Remove the instrument panel top cover and cluster bezel and the right trim panel as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 8E-7. Disconnect the wiring connector to the rear window defogger and fog lamp switch located on the right trim panel, if vehicle is so equipped. 2. Remove 2 mm (approximately 1/16 in.) of material from the upper portion of the left instrument panel clip attachment hole (refer to illustration). 3. Remove the old clip on the right trim panel and install new clip P/N 4796657, on the trim panel with the clip portion facing upward. The new clip has additional material on the bottom surface that will force the panel upward when it is installed on the instrument panel. This will allow a minimum of 3 mm (approximately 1/8 in.) clearance between the right trim panel and steering column cover (refer to illustration). 4. Connect the wiring connector to the rear window defogger and fog lamp switch located on the right trim panel, if disconnected in Step 1. Replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Key Cylinder Lamp: > 084994 > Sep > 94 > Ignition Key Lamp - Lack of Illumination > Page 9828 the right trim panel and instrument panel top as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Page 8E-7. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-50-50-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Tail Lamps and Rear License Plate Lamp License Plate Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp TAIL LAMPS AND REAR LICENSE PLATE LAMP Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to cavity 4 of the headlamp switch. A 40 amp maxi fuse in the PDC protects the A3 circuit. A 15 amp fuse, in cavity 2 of the fuse block, protects the F33 circuit. The headlamp switch has three positions: ON, PARK (tail lamps) and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, it connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps, rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Tail Lamps and Rear License Plate Lamp > Page 9833 License Plate Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp Ground Circuit GROUND CIRCUIT Circuit Z1 provides a ground for the tail lamps, parking lamps, headlamps, side marker lamps, and rear license plate lamp, although different grounding points are used. Circuit Z1 also provides a ground path for the headlamps, stop lamps, and turn signals. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Page 9834 License Plate Lamp: Testing and Inspection ^ Check for a blown 40 amp fuse in the Power Distribution Center (PDC). Check for a blown fuse in cavity 2 of the fuse block. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. ^ Circuit L7 also feeds the radio, if equipped. ^ When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, connects to circuit E1. Circuit E1 powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 amp fuse, in cavity 12 of the fuse block, protects circuit E1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Parking Lamp Parking Lamp: Description and Operation Parking Lamp PARKING LAMPS Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to the headlamp switch. A 40 amp maxi fuse in the PDC protects the A3 circuit. A 15 amp fuse, in cavity 2 of the fuse block, protects the F33 circuit. The headlamp switch has three positions: ON, PARK (parking lamps), and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Parking Lamp > Page 9839 Parking Lamp: Description and Operation Parking Lamp Ground Circuit GROUND CIRCUIT Circuit Z1 provides a ground for the parking lamps, headlamps, tail lamps, side marker lamps, and rear license plate lamp, although different grounding points are used. Circuit Z1 also provides the ground path for the headlamps and turn signals. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Page 9840 Parking Lamp: Testing and Inspection ^ Check for a blown 40 amp maxi fuse in the Power Distribution Center (PDC). ^ Check for a blown fuse in cavity 2 of the fuse block. ^ For the left front parking lamp, turn signal, side marker lamp, and left headlamp, the Z1 circuit grounding point is on the left side of the radiator closure panel. ^ For the right front parking lamp, turn signal, side marker lamp, and right headlamp, the Z1 circuit grounding point is in the right fender side shield. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. ^ Circuit L7 also feeds the radio, if equipped. ^ When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 amp fuse, in cavity 12 of the fuse block, protects circuits E1 and E2. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation DAYTIME RUNNING LAMP (DRL) MODULE - CANADIAN VEHICLES ONLY On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position, and the parking brake switch is open. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 amp maxi fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block that feeds circuit G5 through a 5 amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G5 connects to cavity 1 of the DRL module. Circuit G9 connects to cavity 3 of the DRL module. The G9 circuit splices to the brake warning switch, park brake switch, and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the Power Distribution Center feeds circuit L20. Circuit L20 connects to cavity 6 of the DRL module connector. A 40 amp maxi fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the lowbeams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit L4 originates at cavity 4 of the multi-function switch. The L4 circuit splices to cavity 10 of the DRL module. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fig.21 Power Distribution Center Identification The relay is located in the Power Distribution Center. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: Customer Interest M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211695 > Oct > 95 > M/T - Hard To Shift Into Reverse Backup Lamp Switch: All Technical Service Bulletins M/T - Hard To Shift Into Reverse NO: 21-16-95 GROUP: Transmission EFFECTIVE DATE: Oct. 20, 1995 SUBJECT: Hard To Shift Into Reverse MODELS: 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Stratus 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FJ VEHICLES EQUIPPED WITH A 2.0L DOHC NON-TURBO ENGINE AND JA AND PL VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE AND ALL EQUIPPED WITH A A578 5-SPEED MANUAL TRANSAXLE SYMPTOM/CONDITION: Customer complaint of hard to shift into reverse, or poor shift feel into reverse. PARTS REQUIRED: 1 4864775 Back Up Lamp Switch REPAIR PROCEDURE: This bulletin involves replacing the back up lamp switch with a revised part that requires less load by the 5th/reverse shift fork to actuate. Replace the back up lamp switch, located on the top left front side of the transaxle case, with P/N 4864775 as outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-09-90 Switch, Back-up Lamp - Replace (FJ) 0.3 Hrs. (JA, PL) 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9867 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9868 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9869 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 9874 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9880 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9881 Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 9882 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Backup Lamp Switch: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 9887 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 9888 Backup Lamp Switch: Description and Operation BACK-UP LAMP SWITCH On automatic transmissions, the back-up lamp switch is part of the PARK/NEUTRAL position switch. The back-up lamp switch does not connect to the Powertrain Control Module (PCM) on manual transaxle equipped vehicles. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Technical Service Bulletins > Page 9889 Backup Lamp Switch: Testing and Inspection In the RUN position, the ignition switch connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 30 Amp maxi fuse protects circuits A2 and A22. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 9894 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9895 Stop Lamp Switch: Locations Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9896 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: Customer Interest Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 9905 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: All Technical Service Bulletins Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 9911 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 9920 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Door Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9925 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 9931 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition Door Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 086694 > Nov > 94 > Battery Repeated Discharge Condition > Page 9936 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 amp maxi fuse protects the A3 circuit. The headlamp switch has an internal 24 amp circuit breaker that connects circuit A3 to either the L2 or L20 circuit, depending on switch position. In the OFF and PARK positions, cavity 7 of the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the head-lamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 9941 Headlamp Switch: Description and Operation Headlamp Switch In ON Position HEADLAMP SWITCH IN ON POSITION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low-beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in the fuse block, and power the low-beam headlamps. Circuit L43 supplies current to the left headlamp. Circuit L44 supplies current to the right headlamp. The L43 and L44 circuits each have separate 10 amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high-beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high-beam operation. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 9942 Headlamp Switch: Testing and Inspection ^ Cavity 7 (circuit L20) of the headlamp switch connector is double-crimped to feed the Daytime Running Lamp (DRL) module. ^ Check for a blown fuse in cavity 17 for L43 and in cavity 18 for L44. ^ Check the 40 amp maxi fuse located in the Power Distribution Center (PDC). ^ The headlamp switch has a 24 amp internal circuit breaker. ^ For the left front parking lamp, turn signal, side marker lamp, and left headlamp, the Z1 circuit grounding point is on the left side of the radiator closure panel. ^ For the right front parking lamp, turn signal, side marker lamp, and right headlamp, the Z1 circuit grounding point is in the right fender side shield. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 9943 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9952 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9958 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Tail Lamps and Rear License Plate Lamps Ground Circuit Tail Lamp: Description and Operation Tail Lamps and Rear License Plate Lamps Ground Circuit GROUND CIRCUIT Circuit Z1 provides a ground for the tail lamps, parking lamps, headlamps, side marker lamps, and rear license plate lamp, although different grounding points are used. Circuit Z1 also provides a ground path for the headlamps, stop lamps, and turn signals. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Tail Lamps and Rear License Plate Lamps Ground Circuit > Page 9966 Tail Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp TAIL LAMPS AND REAR LICENSE PLATE LAMP Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to cavity 4 of the headlamp switch. A 40 amp maxi fuse in the PDC protects the A3 circuit. A 15 amp fuse, in cavity 2 of the fuse block, protects the F33 circuit. The headlamp switch has three positions: ON, PARK (tail lamps) and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, it connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps, rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Page 9967 Tail Lamp: Testing and Inspection ^ Check for a blown 40 amp fuse in the Power Distribution Center (PDC). Check for a blown fuse in cavity 2 of the fuse block. ^ For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate, the Z1 circuit grounding point is in the left rear wheel well. ^ For the right rear parking lamp, turn signal, and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. ^ Circuit L7 also feeds the radio, if equipped. ^ When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, connects to circuit E1. Circuit E1 powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 amp fuse, in cavity 12 of the fuse block, protects circuit E1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: Customer Interest Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Trunk Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9977 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition Trunk Lamp Switch: All Technical Service Bulletins Battery - Repeated Discharge Condition NO: 08-66-94 GROUP: Electrical DATE: Nov. 11, 1994 SUBJECT: Discharged Battery Due to Excessive Ignition-Off Current Draw MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: Repeated battery discharge condition due to excessive ignition-off current draw that far exceeds a few milliamps. DIAGNOSIS: Cycle the ignition switch On then Off to terminate the Powertrain Control Module (PCM) oxygen sensor heater test. Remove key from ignition switch. Perform Ignition Off Draw (IOD) test using a test lamp. If the test lamp stays on, the following areas of the vehicle should initially be checked as potential sources of ignition off current draw. A. Glove box lamp staying on with glove box shut. B. Misaligned car doors and/or strikers, resulting in a door not being fully closed causing the interior dome lamp to remain on. C. Interior dome lamp remaining on even though the doors are fully closed due to a missing or damaged door ajar switch bumper pad. D. Trunk lamp remaining on when the trunk lid is closed or a switch that is working in reverse, i.e.; the lamp is off when the trunk lid is open and on when the trunk lid is closed. PARTS REQUIRED: A/R EW42PF8 Glove Box Door Assembly, Driftwood A/R EW42PS6 Glove Box Door Assembly, Quartz A/R 4615952 Door Ajar Switch Bumper Pad A/R 4658809 Trunk Lid Switch/Latch Assembly REPAIR PROCEDURE: This bulletin involves recharging the battery and repairing the item or items causing excessive ignition-off current draw. NOTE: BEFORE REPLACING THE BATTERY OR PROCEEDING WITH ANY REPAIRS, RECHARGE THE BATTERY USING THE PROPER PROCEDURES. ITEM A (GLOVE BOX LAMP): If the glove box lamp will not go off with the glove box partially latched or shut and the switch and/or wiring is not defective, replace the glove box assembly with the appropriate part listed in the Parts Required section. The new part will have a raised pad on the door inner surface approximately 1/8" in height that lines up with the glove box lamp switch. NOTE: IF THE OLD GLOVE BOX DOES HAVE THE RAISED PAD ON THE DOOR, DO NOT REPLACE THE GLOVE BOX ASSEMBLY. ITEM B (MISALIGNED CAR DOORS): Adjust the door and/or striker(s) to minimize the effort required to fully close the doors and maintain the integrity with the surrounding body panels/doors. ITEM C (DOOR AJAR SWITCH BUMPER PAD): Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Trunk Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk Lamp Switch: > 086694 > Nov > 94 > Battery - Repeated Discharge Condition > Page 9983 Replace any damaged or missing door ajar switch bumper pads located on each door with P/N 4615952. ITEM D (TRUNK LAMP): Replace the trunk lid switch/latch assembly with P/N 4658809. NOTE: PERFORM IGNITION OFF DRAW (IOD) TEST AGAIN TO VERIFY THAT THE CURRENT DRAW HAS BEEN ELIMINATED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: Customer Interest Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 9993 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Combination Switch: All Technical Service Bulletins Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 9999 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Technical Service Bulletins > Customer Interest for Turn Signal Indicator: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Turn Signal Indicator: Customer Interest Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Technical Service Bulletins > Customer Interest for Turn Signal Indicator: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 10008 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turn Signal Indicator: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated Turn Signal Indicator: All Technical Service Bulletins Instrument Cluster - Turn Signal Indicators Illuminated NO: 08-15-94 Rev. A GROUP: Electrical EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Turn Signal Indicators Illuminated on Instrument Cluster THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-15-94, DATED APRIL 1, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 (PL) Neon SYMPTOM/CONDITION: A. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. B. The left turn signal indicator on the instrument cluster is illuminated continuously when the ignition is in the run position. C. Both left and right turn signal indicators on the instrument cluster illuminate when activating either the left or right turn signal switch. **D. The left turn signal indicator on the instrument cluster illuminates when the brakes are applied. This may occur after using the left lane change feature if the stalk lever does not return to the neutral position. NOTE: SYMPTOM D APPLIES TO VEHICLES BUILT PRIOR TO 8/23/94, MDH (08-23-XX). DIAGNOSIS: If Symptom A. B or C occurred after the Hazard Warning switch was activated, no repair is necessary (see discussion below). If Symptom D occurred after using the left lane change feature, go to the repair procedure for Symptom D.** SYMPTOM A, B, & C DISCUSSION: The Hazard Warning Button was designed as a two position switch. Left for "On" and right for "Off". If the switch is somewhere in the middle, the above conditions will be noticed. These conditions can be corrected by sliding the switch completely to the right in the "Off" position (See Illustration). **SYMPTOM D PARTS REQUIRED: 1 4793094 Multifunction Switch, Turn Signal/Hazard Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turn Signal Indicator: > 081594A > Aug > 94 > Instrument Cluster - Turn Signal Indicators Illuminated > Page 10014 REPAIR PROCEDURE 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. NOTE: ON NON-TILT STEERING COLUMN IT MAY BE NECESSARY TO REMOVE THE STEERING COLUMN COVER AND LINER TO GAIN ACCESS TO REAR SCREWS ON THE LOWER STEERING COLUMN SHROUD. 3. Remove multifunction switch mounting screw. 4. Disconnect wiring connector. 5. Install new multifunction switch P/N 4793094 and attach the wiring connector. Install the mounting screw and tighten to 17 In.Lbs. (2 N-m). 6. Install the upper and lower steering column shrouds and tighten the retaining screws to 17 In.Lbs. (2 N-m). 7. If removed, install the steering column cover and liner. 6. Reconnect the battery negative cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM D Labor Operation No: 08-85-20-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Description and Operation Underhood Lamp: Description and Operation UNDERHOOD LAMP Circuit M1 from the Power Distribution Center (PDC) supplies battery voltage for the underhood lamp. The underhood lamp portion of circuit M1 has a case- grounded mercury switch in series after the lamp. When the hood is raised, mercury inside the switch moves to a position where it connects circuit M1 to ground, illuminating the lamp. The underhood lamp is wired in parallel with other components on circuit M1. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Description and Operation Vanity Lamp: Description and Operation VISOR/VANITY LAMPS The visor/vanity lamps are case-grounded, and are operated by a switch internal to the assembly. Power for the lamps is on the M1 circuit from the Power Distribution Center (PDC). When the operator lifts the cover on the lamp, the switch closes, completing a path to ground. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions Rear Window Defogger: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 Fig.5 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10033 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Power Distribution Center Identification Fig.21 Power Distribution Center Identification For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to the wiring diagrams. Wire Circuit and Gauge Identification Fig.1 Wire Color Code Identification Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10034 Fig.2 Wire Color Codes Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10035 Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10036 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10037 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10038 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10039 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10040 ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10041 Rear Window Defogger: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 Heated Rear Window Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Page 10045 Rear Window Defogger: Description and Operation HEATED REAR WINDOW The Heated Rear Window system is powered by a 30 amp maxi fuse located in the Power Distribution Center (PDC) on circuit A4. This circuit is HOT at all times. The system is also powered by a 10 amp fuse located in cavity 8 of the fuse block. This fuse is HOT in the RUN position only. When the operator presses the Heated Rear Window switch, contacts internal to the switch close, and the timer starts. When the switch is released, the timer circuitry keeps the relay energized for the specified time. Current flows through the switch on the A4 circuit to the C15 circuit, and then to the Heated Rear Window Grid. The grid consists of two bus bars and grid lines that form a parallel circuit. When current flows through the grid, the grid lines heat up and transfer the heat to the rear window. Grounding for the Heated Rear Window switch is provided on the Z2 circuit, and terminates at the instrument panel right center support. The grid uses the grounding point at the rear body in the right wheel house. When the system is in operation, an LED located in the switch, indicates to the operator that the system is functioning. The switch is also illuminated When the headlamp switch is in the PARK or ON position. Power for the illumination circuit comes from the 4 amp fuse, located in cavity 12 of the fuse block, on the E2 circuit. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Page 10046 Rear Window Defogger: Testing and Inspection - Check the 30 Amp maxi fuse in the (PDC). - Check the 10 Amp fuse in cavity 8 of the fuse block. - Check for broken grid lines on the window. - Check for a broken bus bar or disconnected leads at the rear window. - Check for a good ground at the rear body ground located in the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner and outer door belt weatherstrips. 3. Loosen inner belt stabilizer. 4. Lower door glass to bottom of travel to access glass attachment bolts. Regulator Lift Channel 5. Remove bolts holding regulator lift channel to door glass. Guide Bolts 6. Remove bolts holding rear guide plate to door glass. 7. Separate rear guide plate from door glass. Door Glass Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 10052 8. Lift door glass upward and out of opening at top of door. 9. Remove front guide plate from door glass. INSTALLATION 1. Install front guide plate to door glass. 2. Carefully lower door glass through opening in top of door. 3. Position rear guide plate onto door glass and install bolts. 4. Install nuts holding regulator lift channel to door glass. 5. Tighten all door glass fasteners. 6. Tighten window inner belt stabilizer. 7. Install inner and outer door belt weatherstrips. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner door belt weatherstrip. 3. Loosen door glass jounce bumper. 4. Lower door glass to bottom of door. Rear Door Glass 5. Remove nuts holding door glass to window regulator lift plate. 6. Disengage door glass from regulator. 7. Lift door glass upward out of the opening at the top of door. INSTALLATION 1. Lower door glass through opening in top of door and into position in the window regulator. 2. Install nuts holding door glass to window regulator lift plate. 3. Raise glass and tighten window inner belt stabilizer. 4. Install inner door belt weatherstrip, watershield and door trim panel. 5. Operate window and check for interference. Adjust glass as necessary Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort Window Regulator: Customer Interest Front Manual Windows - High Operation Effort NO: 23-92-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: High Effort to Operate Front Manual Windows MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FOUR DOOR VEHICLES BUILT PRIOR TO SEP. 20, 1994 (MDH 09-20-XX). SYMPTOM/CONDITION: Customer complaint of high effort to operate front manual windows. DIAGNOSIS: Evaluate the window system for obvious out of adjustment conditions. The glass should track in the center of the mirror stanchion. The inner belt stabilizer should touch the glass with slight pressure to provide an anti-rattle effect. The face of the glass stabilizer should be parallel to the glass to avoid a pinching effect. If the window system does not conform to these requirements, proceed to the repair procedure. PARTS REQUIRED: AR 4549615 Mopar Lubriplate A/R 4658978 Window Regulator-Right Front Door A/R 4658979 Window Regulator-Left Front Door REPAIR PROCEDURE: This bulletin involves modifying the right and/or left inner belt weatherstrip, adjusting the window as necessary and lubricating the window regulator rails. 1. Remove the door trim panel. If the glass is out of adjustment as identified in the diagnosis section, adjust the glass as necessary. NOTE: THE GLASS SHOULD BE IN LINE WITH THE MIRROR STANCHION AND SLIGHTLY HIGH TO THE TOP OF THE STANCHION BY 1/16 IN. (2 MM) (FIGURE 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort > Page 10064 2. With the window in the full up position, using Mopar Lubriplate, P/N 4549615, or equivalent, lubricate the entire length of each regulator rail on all four sides that come in contact with the plastic guides on both lift plates. 3. Remove the front door inner belt weatherstrip. Remove the entire length of the lower lip with a utility knife. Install the modified weatherstrip on the door (Figure 2). Do not install the trim panel at this time. 4. Loosen the two rear glass-to-lift-plate attaching screws so the washers are free to move. With the window half way open, crank the window up and down a few inches several times and then tighten the screws to a maximum of 50 In.Lbs. (5.5 N-m). NOTE: OVER TORQUING COULD RESULT IN GLASS BREAKAGE. 5. Check to ensure that the glass fit to the door opening weatherstrip is correct. 6. Evaluate the window crank effort. If it is still excessive, replace the window regulator with the appropriate part called out in the parts required section. 7. Replace the door trim panel and attaching components. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Door Inner Belt Weatherstrip Modify, Adjust Window & Lubricate Window Regulator Rails 23-51-17-95 0.6 Hrs. Failure Code: XX - Service Adjustment Window Regulator, front Door Glass, Right Side 23-34-10-98 0.5 Hrs. Window Regulator, front Door Glass, Left Side 23-34-10-99 0.5 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 239294 > Dec > 94 > Front Manual Windows High Operation Effort Window Regulator: All Technical Service Bulletins Front Manual Windows - High Operation Effort NO: 23-92-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: High Effort to Operate Front Manual Windows MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FOUR DOOR VEHICLES BUILT PRIOR TO SEP. 20, 1994 (MDH 09-20-XX). SYMPTOM/CONDITION: Customer complaint of high effort to operate front manual windows. DIAGNOSIS: Evaluate the window system for obvious out of adjustment conditions. The glass should track in the center of the mirror stanchion. The inner belt stabilizer should touch the glass with slight pressure to provide an anti-rattle effect. The face of the glass stabilizer should be parallel to the glass to avoid a pinching effect. If the window system does not conform to these requirements, proceed to the repair procedure. PARTS REQUIRED: AR 4549615 Mopar Lubriplate A/R 4658978 Window Regulator-Right Front Door A/R 4658979 Window Regulator-Left Front Door REPAIR PROCEDURE: This bulletin involves modifying the right and/or left inner belt weatherstrip, adjusting the window as necessary and lubricating the window regulator rails. 1. Remove the door trim panel. If the glass is out of adjustment as identified in the diagnosis section, adjust the glass as necessary. NOTE: THE GLASS SHOULD BE IN LINE WITH THE MIRROR STANCHION AND SLIGHTLY HIGH TO THE TOP OF THE STANCHION BY 1/16 IN. (2 MM) (FIGURE 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 239294 > Dec > 94 > Front Manual Windows High Operation Effort > Page 10070 2. With the window in the full up position, using Mopar Lubriplate, P/N 4549615, or equivalent, lubricate the entire length of each regulator rail on all four sides that come in contact with the plastic guides on both lift plates. 3. Remove the front door inner belt weatherstrip. Remove the entire length of the lower lip with a utility knife. Install the modified weatherstrip on the door (Figure 2). Do not install the trim panel at this time. 4. Loosen the two rear glass-to-lift-plate attaching screws so the washers are free to move. With the window half way open, crank the window up and down a few inches several times and then tighten the screws to a maximum of 50 In.Lbs. (5.5 N-m). NOTE: OVER TORQUING COULD RESULT IN GLASS BREAKAGE. 5. Check to ensure that the glass fit to the door opening weatherstrip is correct. 6. Evaluate the window crank effort. If it is still excessive, replace the window regulator with the appropriate part called out in the parts required section. 7. Replace the door trim panel and attaching components. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Door Inner Belt Weatherstrip Modify, Adjust Window & Lubricate Window Regulator Rails 23-51-17-95 0.6 Hrs. Failure Code: XX - Service Adjustment Window Regulator, front Door Glass, Right Side 23-34-10-98 0.5 Hrs. Window Regulator, front Door Glass, Left Side 23-34-10-99 0.5 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door Window Regulator: Service and Repair Front Door Window Regulator - 4 Door NOTE: Power and manual door glass regulators are serviced using the same procedures. For power window motor service procedures, refer to Power Window Motor/Service and Repair. REMOVAL 1. Remove door trim panel and water shield. 2. Remove door glass. 3. Disconnect wire connector to power window motor, if so equipped. 4. Remove nuts holding top of regulator to inner door panel. Front Door Manual Window Regulator Front Door Power Window Regulator 5. Remove nuts holding bottom of regulator to door panel. 6. Loosen bolts holding regulator crank/motor to door panel. 7. Disengage bolts from key hole slots in door panel. 8. Remove window regulator from access hole in door panel. 9. Remove power window motor from regulator, if so equipped. Refer to Power Window Motor/Service and Repair. INSTALLATION 1. Install power window motor on regulator, if so equipped. Refer to Power Window Motor/Service and Repair. 2. Move window regulator into position in door and engage bolt heads in key-slots in inner door panel. 3. Tighten bolts attaching regulator crank/motor to door panel. 4. Install nuts holding top and bottom of window regulator to door panel. 5. Install door glass. Refer to adjustment procedures to verify and adjust glass alignment. 6. Connect wire connector to power window motor, if so equipped. 7. install door speaker, if so equipped. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 10073 Window Regulator: Service and Repair Rear Door Window Regulator - 4 Door REMOVAL 1. Remove door trim panel and watershield. 2. Remove door glass. 3. Loosen bolts holding window regulator crank/ motor to door panel. 4. Disengage bolt heads from keyhole slots in door panel. 5. Loosen bolts holding window regulator lift bar to door panel. Rear Door Window Regulator 6. Disengage bolt heads from keyhole slots in door panel. 7. Remove window regulator from door through access hole in inner panel. INSTALLATION 1. Move window regulator into position and engage bolt heads into key-hole slots in inner door panel. 2. Tighten bolts holding window regulator lift bar to inner door panel. 3. Engage window regulator crank/motor bolts into key-hole slots in door panel. 4. Tighten window regulator crank/motor bolts. 5. Install door glass, watershield, and door trim panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 10074 Window Regulator: Service and Repair 2 Door Models NOTE: Power and manual door glass regulators are serviced using the same procedures. For power window motor service procedures, refer to Power Window Motor/Service and Repair. REMOVAL 1. Remove door trim panel and water shield. refer to Door Panel/Service and Repair. 2. Disconnect wire connector to power window motor, if so equipped. Regulator Lift Channel 3. Remove nuts holding regulator lift channel to door glass. 4. Secure door glass in upward position. 5. Mark position of rear bolt of roller channel to inner door panel to aid in installation. 6. Remove bolt holding rear of roller channel to door panel. 7. Loosen bolt holding front of roller channel to door panel. Roller Channel 8. Separate roller channel from door panel. 9. Loosen bolts holding window regulator to inner door panel. 10. Separate bolt heads from key-hole slots in inner door panel. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 10075 Manual Window Regulator Power Window Regulator 11. Remove window regulator through large hole in inner door panel. 12. Remove power window motor from regulator, if so equipped. Refer to Power Window Motor/Service and Repair. INSTALLATION 1. Install power window motor on regulator, if so equipped. Refer to Power Window Motor/Service and Repair. 2. Move window regulator into position in door and engage bolt heads into key-hole slots in inner door panel and tighten bolts. 3. Install roller channel to door panel. 4. Install bolt at rear of roller channel. Make sure that bolt is aligned to mark on inner door panel made previously 5. Tighten front and rear bolts of roller channel. 6. Install nuts holding regulator lift channel to door glass. 7. Adjust door glass as described in this section. 8. Connect wire connector to power window motor, if so equipped. 9. Install door speaker, if so equipped. 10. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 10084 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 10085 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort Window Seal: Customer Interest Front Manual Windows - High Operation Effort NO: 23-92-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: High Effort to Operate Front Manual Windows MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FOUR DOOR VEHICLES BUILT PRIOR TO SEP. 20, 1994 (MDH 09-20-XX). SYMPTOM/CONDITION: Customer complaint of high effort to operate front manual windows. DIAGNOSIS: Evaluate the window system for obvious out of adjustment conditions. The glass should track in the center of the mirror stanchion. The inner belt stabilizer should touch the glass with slight pressure to provide an anti-rattle effect. The face of the glass stabilizer should be parallel to the glass to avoid a pinching effect. If the window system does not conform to these requirements, proceed to the repair procedure. PARTS REQUIRED: AR 4549615 Mopar Lubriplate A/R 4658978 Window Regulator-Right Front Door A/R 4658979 Window Regulator-Left Front Door REPAIR PROCEDURE: This bulletin involves modifying the right and/or left inner belt weatherstrip, adjusting the window as necessary and lubricating the window regulator rails. 1. Remove the door trim panel. If the glass is out of adjustment as identified in the diagnosis section, adjust the glass as necessary. NOTE: THE GLASS SHOULD BE IN LINE WITH THE MIRROR STANCHION AND SLIGHTLY HIGH TO THE TOP OF THE STANCHION BY 1/16 IN. (2 MM) (FIGURE 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort > Page 10090 2. With the window in the full up position, using Mopar Lubriplate, P/N 4549615, or equivalent, lubricate the entire length of each regulator rail on all four sides that come in contact with the plastic guides on both lift plates. 3. Remove the front door inner belt weatherstrip. Remove the entire length of the lower lip with a utility knife. Install the modified weatherstrip on the door (Figure 2). Do not install the trim panel at this time. 4. Loosen the two rear glass-to-lift-plate attaching screws so the washers are free to move. With the window half way open, crank the window up and down a few inches several times and then tighten the screws to a maximum of 50 In.Lbs. (5.5 N-m). NOTE: OVER TORQUING COULD RESULT IN GLASS BREAKAGE. 5. Check to ensure that the glass fit to the door opening weatherstrip is correct. 6. Evaluate the window crank effort. If it is still excessive, replace the window regulator with the appropriate part called out in the parts required section. 7. Replace the door trim panel and attaching components. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Door Inner Belt Weatherstrip Modify, Adjust Window & Lubricate Window Regulator Rails 23-51-17-95 0.6 Hrs. Failure Code: XX - Service Adjustment Window Regulator, front Door Glass, Right Side 23-34-10-98 0.5 Hrs. Window Regulator, front Door Glass, Left Side 23-34-10-99 0.5 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 10096 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 10097 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort Window Seal: All Technical Service Bulletins Front Manual Windows - High Operation Effort NO: 23-92-94 GROUP: Body DATE: Dec. 9, 1994 SUBJECT: High Effort to Operate Front Manual Windows MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO FOUR DOOR VEHICLES BUILT PRIOR TO SEP. 20, 1994 (MDH 09-20-XX). SYMPTOM/CONDITION: Customer complaint of high effort to operate front manual windows. DIAGNOSIS: Evaluate the window system for obvious out of adjustment conditions. The glass should track in the center of the mirror stanchion. The inner belt stabilizer should touch the glass with slight pressure to provide an anti-rattle effect. The face of the glass stabilizer should be parallel to the glass to avoid a pinching effect. If the window system does not conform to these requirements, proceed to the repair procedure. PARTS REQUIRED: AR 4549615 Mopar Lubriplate A/R 4658978 Window Regulator-Right Front Door A/R 4658979 Window Regulator-Left Front Door REPAIR PROCEDURE: This bulletin involves modifying the right and/or left inner belt weatherstrip, adjusting the window as necessary and lubricating the window regulator rails. 1. Remove the door trim panel. If the glass is out of adjustment as identified in the diagnosis section, adjust the glass as necessary. NOTE: THE GLASS SHOULD BE IN LINE WITH THE MIRROR STANCHION AND SLIGHTLY HIGH TO THE TOP OF THE STANCHION BY 1/16 IN. (2 MM) (FIGURE 1). Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 239294 > Dec > 94 > Front Manual Windows - High Operation Effort > Page 10102 2. With the window in the full up position, using Mopar Lubriplate, P/N 4549615, or equivalent, lubricate the entire length of each regulator rail on all four sides that come in contact with the plastic guides on both lift plates. 3. Remove the front door inner belt weatherstrip. Remove the entire length of the lower lip with a utility knife. Install the modified weatherstrip on the door (Figure 2). Do not install the trim panel at this time. 4. Loosen the two rear glass-to-lift-plate attaching screws so the washers are free to move. With the window half way open, crank the window up and down a few inches several times and then tighten the screws to a maximum of 50 In.Lbs. (5.5 N-m). NOTE: OVER TORQUING COULD RESULT IN GLASS BREAKAGE. 5. Check to ensure that the glass fit to the door opening weatherstrip is correct. 6. Evaluate the window crank effort. If it is still excessive, replace the window regulator with the appropriate part called out in the parts required section. 7. Replace the door trim panel and attaching components. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Door Inner Belt Weatherstrip Modify, Adjust Window & Lubricate Window Regulator Rails 23-51-17-95 0.6 Hrs. Failure Code: XX - Service Adjustment Window Regulator, front Door Glass, Right Side 23-34-10-98 0.5 Hrs. Window Regulator, front Door Glass, Left Side 23-34-10-99 0.5 Hrs. Failure Code: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair FRONT VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt holding top of front guide bar to inner door panel. Front Vertical Guide Bar 5. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Front Guide 6. Remove front vertical guide bar through speaker hole in inner door panel. 7. Reverse the preceding operation for installation. Verify door glass alignment, adjust if necessary. REAR VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove nut holding top of rear guide bar to inner door panel. 3. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Page 10106 Rear Vertical Guide Bar 4. Remove rear vertical guide bar through large access bole in inner door panel. 5. Reverse the preceding operations and verify glass alignment. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out Windshield: Customer Interest Backlight/Windshield Moulding - Glue Oozing Out NO: 23-68-94 GROUP: Body DATE: Sep. 30, 1994 SUBJECT: Glue Oozes Out at Backlight or Windshield Molding MODELS: 1994 - 1995 (AN) Dakota 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (BR) Ram Truck 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 (JA) Cirrus/Stratus 1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon SYMPTOM/CONDITION: A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or windshield molding and collects at the bottom corners of the moldings. The material could also be seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt at a lower temperature thus running down the sides of the glass to the bottom of the molding. DIAGNOSIS: Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is visible, perform the repair procedure. PARTS REQUIRED: AR 4318067 Solvent, Mopar Concentrated Windshield Washer REPAIR PROCEDURE: This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and molding. 1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N 4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up with a cloth. 2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer concentrate to get under the molding and run along the edge of the glass to remove as much of the hot melt glue as possible. If most of the glue is not removed, the condition will reoccur. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-50-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out Windshield: All Technical Service Bulletins Backlight/Windshield Moulding - Glue Oozing Out NO: 23-68-94 GROUP: Body DATE: Sep. 30, 1994 SUBJECT: Glue Oozes Out at Backlight or Windshield Molding MODELS: 1994 - 1995 (AN) Dakota 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (BR) Ram Truck 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 (JA) Cirrus/Stratus 1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon SYMPTOM/CONDITION: A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or windshield molding and collects at the bottom corners of the moldings. The material could also be seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt at a lower temperature thus running down the sides of the glass to the bottom of the molding. DIAGNOSIS: Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is visible, perform the repair procedure. PARTS REQUIRED: AR 4318067 Solvent, Mopar Concentrated Windshield Washer REPAIR PROCEDURE: This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and molding. 1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N 4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up with a cloth. 2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer concentrate to get under the molding and run along the edge of the glass to remove as much of the hot melt glue as possible. If most of the glue is not removed, the condition will reoccur. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-50-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Customer Interest for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: Customer Interest Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: All Technical Service Bulletins Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Page 10135 Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Page 10136 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove three screws from steering column shroud and remove upper half of shroud. 3. Remove mounting screws on switch and remove switch. 4. Disconnect electrical connector from switch. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 081196 > Apr > 96 > Windshield Washers - Delayed Washer Fluid Output Windshield Washer Hose: Customer Interest Windshield Washers - Delayed Washer Fluid Output NO: 08-11-96 GROUP: Electrical DATE: Apr. 12, 1996 SUBJECT: Delayed Washer Fluid Output MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Delayed washer fluid output from one or both washer nozzles when wash button is depressed. PARTS REQUIRED: 2 4805010 Check Valve, Windshield Washer REPAIR PROCEDURE: This bulletin involves the installation of a new windshield washer hose check valve at the nozzle. 1. Disconnect both washer hoses from the washer nozzle. 2. Remove the check valve from one hose. 3. Install the new check valve (white in color) (P/N 4805010) with the end housing the check ball toward the reservoir and the open end toward the nozzle. 4. Repeat steps 2 and 3 for the other side. 5. Connect the hose/check valve assemblies to the nozzle. 6. Verify proper windshield washer operation. If the fluid does not flow properly, check the hose to insure there are no kinks or pinched areas and insure check valve is installed in the proper direction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-14-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 081196 > Apr > 96 > Windshield Washers - Delayed Washer Fluid Output Windshield Washer Hose: All Technical Service Bulletins Windshield Washers - Delayed Washer Fluid Output NO: 08-11-96 GROUP: Electrical DATE: Apr. 12, 1996 SUBJECT: Delayed Washer Fluid Output MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Delayed washer fluid output from one or both washer nozzles when wash button is depressed. PARTS REQUIRED: 2 4805010 Check Valve, Windshield Washer REPAIR PROCEDURE: This bulletin involves the installation of a new windshield washer hose check valve at the nozzle. 1. Disconnect both washer hoses from the washer nozzle. 2. Remove the check valve from one hose. 3. Install the new check valve (white in color) (P/N 4805010) with the end housing the check ball toward the reservoir and the open end toward the nozzle. 4. Repeat steps 2 and 3 for the other side. 5. Connect the hose/check valve assemblies to the nozzle. 6. Verify proper windshield washer operation. If the fluid does not flow properly, check the hose to insure there are no kinks or pinched areas and insure check valve is installed in the proper direction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-14-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers Wiper Motor: Testing and Inspection Standard Wipers Important Information - Read First Whenever a wiper motor malfunction occurs, first ensure wiper motor wire harness is properly connected before starting with normal diagnosis and repair procedures. Motor Will Not Operate In Some or All Switch Positions 1. Check fuse No. 15 in fuse block: a. If fuse is OK proceed to next step. b. If fuse is bad, replace, then check wiper functions in all switch positions. If fuse blows again, proceed to voltmeter test step below. c. If replaced fuse does not blow and motor does not run, proceed to next step. Fig.7 Wiper Motor Connector 2. Disconnect motor connector, and perform the following tests: a. Connect jumper wire from battery negative terminal to motor ground strap. b. Connect jumper wire from battery positive terminal to pin two of connector, then move jumper wire from battery positive terminal to pin one of connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10167 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10168 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) c. If motor runs OK check wiring circuits. Check wiper switch. d. If motor does not run proceed to next step. 3. Using a suitable ohmmeter check ground strap at motor: a. If ground strap is OK, replace motor. b. If not OK, repair ground as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10169 4. Using a suitable voltmeter, with wiper switch connected: Fig.9 Wiper Switch Tests a. Connect voltmeter positive lead to terminal P1, and negative lead to motor ground. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10170 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10171 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) b. If no voltage, repair wiring circuits as necessary. c. If voltage is OK, connect voltmeter positive lead to wiper switch terminal L, then move switch to low speed position. If no voltage replace switch. d. Repeat above test for wiper switch terminal H. e. If all tests OK, proceed to next step. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10172 5. Disconnect motor connector, then replace fuse fifteen in fuse block: a. If fuse does not blow, replace motor. b. If fuse blows, disconnect wiper switch and replace fuse fifteen in fuse block. c. If fuse does not blow replace switch. Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10173 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) d. If fuse blows, check and repair wiring circuits, as necessary. Wipers Do Not Operate In Washer or Pulse Mode Using a suitable ohmmeter check motor ground, if OK replace wiper switch. If not OK, repair ground. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10174 Wipers Operate Slowly at All Speeds Refer to Testing and Inspection/Procedures/Inspection See: Wiper Motor Runs Slow Wipers Run Fast In Low Position or Slow In Fast Position Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10175 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Check for crossed wires in wiper motor connectors. 2. Check for crossed wires in wiper switch connectors. 3. If OK replace wiper switch. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10176 Wiper Motor: Testing and Inspection Intermittent Wiper System Important Information - Read First The intermittent wipe function is controlled by the body controller, located in the passenger compartment behind the right side kick panel. To diagnose system malfunctions that do not involve the delay function, refer to "Standard Front Wipers" in this section. Motor Will Not Operate In Some or All Switch Positions 1. Check fuse fifteen in fuse block: a. If fuse is OK proceed to next step. b. If fuse is bad, replace, then check wiper functions in all switch positions. If fuse blows again proceed to voltmeter test step below. c. If replaced fuse does not blow and motor does not run, proceed to next step. Fig.7 Wiper Motor Connector 2. Disconnect motor connector, perform the following tests: a. Connect jumper wire from battery negative terminal to motor ground strap. b. Connect jumper wire from battery positive terminal to pin two of connector, then move jumper wire from battery positive terminal to pin one of connector. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10177 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10178 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) c. If motor runs OK, check wiring circuits, and wiper switch as outlined under "Component Diagnosis & Testing." d. If motor does not run, proceed to next step. 3. Using a suitable ohmmeter, check ground strap at motor as follows: a. If ground strap is OK, replace motor. b. If not OK, repair ground as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10179 Fig.9 Wiper Switch Tests 4. Using a suitable ohmmeter, check continuity from terminal E of wiper switch, to ground: a. If OK, proceed to next step. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10180 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10181 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) b. If not OK, repair wiring circuit to ground. 5. Using a suitable voltmeter, with wiper switch connected: a. Connect voltmeter positive lead to terminal P1, and negative lead to motor ground. b. If no voltage, repair wiring circuits as necessary. c. If voltage is OK, connect voltmeter positive lead to wiper switch terminal L, then move switch to low speed position. If no voltage replace Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10182 switch. d. Repeat above test for wiper switch terminal H. e. If all tests OK, proceed to next step. 6. Disconnect motor connector, then replace fuse fifteen in fuse block: a. If fuse does not blow, replace motor. b. If fuse blows, disconnect wiper switch and replace fuse fifteen in fuse block. c. If fuse does not blow replace switch. d. If fuse blows, check and repair wiring circuits, as necessary. Runs Continuously In Intermittent Mode/Will Not "Park" Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10183 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10184 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Using a suitable ohmmeter, check motor ground and repair if necessary. 2. With ignition switch in OFF position and wiper motor in park position: Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10185 Fig.7 Wiper Motor Connector a. Using a suitable ohmmeter, check for continuity between pin three of wiper motor connector, and ground. b. If OK, replace wiper switch. c. If not OK, repair wiring circuits as necessary. Wipers Do Not Operate In Washer, Pulse or Intermittent Mode Fig.9 Wiper Switch Tests Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10186 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10187 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Using a suitable ohmmeter, check motor ground and continuity from terminal E of wiper switch, to ground. 2. If OK, replace wiper switch. 3. If not OK, repair wiring circuit as necessary. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10188 Wiper Motor: Testing and Inspection Wiper Motor Runs Slow 1. Remove wiper arms and cowl panel. 2. Disconnect wiper linkage and wiring connector from motor. Fig.82 Wiper Motor Current Test 3. Connect a suitable ammeter between motor and battery positive terminal. 4. With motor running, if current draw is greater than six amps, check for binding in shafts and linkage. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10189 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 10190 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 5. With motor running, if current draw is less than six amps, use a suitable ohmmeter and check wiper circuits for short to ground. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 10191 Wiper Motor: Service and Repair 1. Disconnect battery ground cable. 2. Remove wiper arms and blades. 3. Remove rear hood seal and cowl screen. 4. Remove electrical connector at wiper motor. 5. Remove mounting screws from wiper assembly. 6. Disconnect wiper linkage from bellcrank on wiper motor. 7. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Customer Interest for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: Customer Interest Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Switch: > 082494 > May > 94 > Wipers - Operate By Themselves Intermittently Wiper Switch: All Technical Service Bulletins Wipers - Operate By Themselves Intermittently NO: 08-24-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Intermittent Wiper Operation MODELS: 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO APRIL 15, 1994, (MDH 04-15-XX), EQUIPPED WITH INTERMITTENT WIPERS. SYMPTOM/CONDITION: Wipers may cycle once or twice and return to the park position, without operating the wiper switch. This can be caused by external radio frequency interference (R.F.I.), i.e.; CB radio or commercial transmitting antennas. The wiper switch will function normally otherwise, in all operating modes. PARTS REQUIRED: 1 4661943 Switch, Intermittent Wiper REPAIR PROCEDURE: This bulletin involves replacing the wiper switch with a revised part. 1. Remove three screws holding the steering column shroud, and remove upper half of the shroud. 2. Remove the mounting screw on the switch, and remove the switch. 3. Disconnect the wiring harness connector from the switch. 4. Install the new wiper switch P/N 4661943 by reconnecting the wiring harness connector, installing the mounting screw, and reinstalling the upper half of the steering column shroud. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-90-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L SOHC (1995)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Technical Service Bulletins > Page 10205 Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown.