DODGE NEON 1997 1.G Wiring Diagrams User Guide

Downloaded from www.Manualslib.com manuals search engine CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove the connector locking wedge, if
required (Fig. 16)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 17) (Fig. 18).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 19).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra lengthfor soldered connections. Check that the overall
length is the same as the original (Fig. 19).
(7) Remove 1 inch of insulation from each wire.
Fig. 16 Connector Locking Wedge
Fig. 17 Terminal Removal
Fig. 18 Terminal Removal Using Special Tool
Fig. 19 Stagger Cutting Wires
PL8W - 01 GENERAL INFORMATION 8W - 01 - 9
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 20).
(3) Remove connector locking wedge, if required
(Fig. 20).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 21) (Fig. 22).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires.
(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
Fig. 20 Connector Locking Wedge Tab (Typical)
Fig. 21 Terminal Removal
Fig. 22 Terminal Removal Using Special Tool
8W - 01 - 10 8W - 01 GENERAL INFORMATIONPL
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 23).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys-
tems.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 23 Diode Identification
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
PL8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)

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Downloaded from www.Manualslib.com manuals search engine 8W-02 COMPONENT INDEX
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION.......................................................... 3
Component Page
A/C Compressor Clutch.................8W-42
A/C Compressor Clutch Relay............8W-42
A/C Cycling Switch....................8W-42
A/C Heater Blower Motor................8W-42
A/C Heater Control Switch...............8W-42
A/C High Pressure Switch...............8W-42
A/C Low Pressure Switch................8W-42
ABS Hydraulic Modulator...............8W-35
ABS Pump Motor......................8W-35
ABS Pump Motor Relay.................8W-35
ABS Relay Box........................8W-35
ABS System Relay.....................8W-35
ABS Warning Lamp....................8W-35
Airbag Control Module..................8W-43
Airbag Impact Sensors..................8W-43
Airbag Warning Lamp..................8W-40
Antenna.............................8W-47
Anti-Lock Warning Lamp................8W-40
Ash Receiver Lamp....................8W-44
Automatic Shut Down Relay.............8W-30
Back-Up Lamp Switch..................8W-51
Back-Up Lamps.......................8W-51
Battery..............................8W-20
Battery Temperature Sensor.............8W-30
Blower Motor Resistor Block.............8W-42
Brake Warning Lamp...................8W-40
Brake Warning Lamp Switch.............8W-40
Camshaft Position (CMP) Sensor..........8W-30
Capacitor.........................8W-10, 20
Charge Indicator Lamp.................8W-40
Check Engine Lamp....................8W-40
Cigar Lighter Relay....................8W-41
Cigar Lighter/Power Outlet..............8W-41
Circuit Breaker.....................8W-11,62
Circuit Breaker (FB)...................8W-11
Clockspring..........................8W-41
Cluster Illumination Lamps..............8W-40
Clutch Pedal Position Switch..........8W-10, 21
Combination Flasher...................8W-52
Controller Anti-Lock Brake..............8W-35
Crankshaft Position (CKP) Sensor.........8W-30
Data Link Connector...................8W-30
Diode............................8W-15, 42
Dome Lamp..........................8W-44Component Page
Door Ajar Switches.....................8W-44
Door Jamb Switches....................8W-40
Door Lock Motors......................8W-61
Door Lock Switches....................8W-61
Door Speakers........................8W-47
Driver Side Airbag.....................8W-43
Duty Cycle Evap/Purge Solenoid..........8W-30
EGR Transducer Solenoid...............8W-30
Engine Coolant Temperature (ECT) Sensor . . 8W-30
Engine Coolant Temperature Gauge.......8W-40
Engine Oil Pressure Switch..............8W-40
Engine Starter Motor...................8W-21
Engine Starter Motor Relay..............8W-21
Fog Lamp Relay....................8W-50, 51
Fog Lamps........................8W-50, 51
Front Fog Lamp Switch.................8W-50
Fuel Gauge...........................8W-40
Fuel Injectors.........................8W-30
Fuel Pump Module.....................8W-30
Fuel Pump Relay......................8W-30
Fuse Block...........................8W-11
Fuses (FB)...........................8W-11
Fuses (PDC)..........................8W-10
Fusible Link.......................8W-20, 21
Generator............................8W-20
Glove Box Lamp And Switch.............8W-44
Ground Distribution....................8W-15
Headlamp Dimmer And Optical
Horn Switch........................8W-50
Headlamp Leveling Motors..............8W-50
Headlamp Leveling Switch...............8W-50
Headlamp Switch......................8W-50
Headlamps...........................8W-50
Heated Oxygen Sensors.................8W-30
High Beam Indicator Lamp..............8W-40
Horn Relay...........................8W-41
Horn Switches........................8W-41
Horns...............................8W-41
IAT/MAP Sensor......................8W-30
Idle Air Control (IAC) Motor.............8W-30
Ignition Coil Pack.....................8W-30
Ignition Switch........................8W-10
Immobilizer Engine Sensor..............8W-30
Immobilizer Sensor....................8W-30
PL8W - 02 COMPONENT INDEX 8W - 02 - 1

Downloaded from www.Manualslib.com manuals search engine Component Page
Instrument Cluster....................8W-40
Instrument Panel Speakers..............8W-47
Intermittent Wipe/Wash Switch...........8W-53
Key-In Switch........................8W-40
Knock Sensor.........................8W-30
License Lamps........................8W-51
Low Oil Pressure Lamp.................8W-40
Map/Reading Lamps...................8W-44
Master Power Window Switch............8W-60
Mercury Switch.......................8W-44
Noise Supressor.......................8W-30
Park Brake Switch.....................8W-40
Park/Neutral Position Switch.............8W-51
Park/Turn Signal Lamps................8W-52
Passenger Side Airbag..................8W-43
Power Distribution Center...............8W-10
Power Folding Mirror Relay..............8W-62
Power Mirror Fuse Holder...............8W-62
Power Mirror Switch...................8W-62
Power Mirrors........................8W-62
Power Steering Pressure Switch..........8W-30
Power Sunroof Motor...................8W-64
Power Window Motors..................8W-60
Power Window Switches.................8W-60
Powertrain Control Module..............8W-30
PRNDL Lamp........................8W-44
Pump Motor Driver....................8W-35
Radiator Fan Motor....................8W-42Component Page
Radio...............................8W-47
Rear Fog Lamp Switch..................8W-51
Rear Window Defogger..................8W-48
Rear Window Defogger Switch............8W-48
Repeater Lamps....................8W-50, 52
Seat Belt Warning Lamp................8W-40
Solid State Fan Relay..................8W-42
Speakers............................8W-47
Splice Information.....................8W-30
Stop Lamp Switch.....................8W-30
Sunroof Slide Switch...................8W-64
Sunroof Vent Switch....................8W-64
Switch Illumination....................8W-48
Tail/Stop Lamps.......................8W-51
Throttle Position (TP) Sensor.............8W-30
Torque Converter Clutch Solenoid.........8W-30
Trunk Lamp..........................8W-44
Trunk Switch.........................8W-44
Turn Indicator Lamps..................8W-40
Turn Signal Lamps....................8W-52
Turn Signal/Hazard Switch..............8W-52
Underhood Lamp......................8W-44
Vapor Canister Leak Detector............8W-30
Vehicle Speed Sensor...................8W-30
Visor/Vanity Lamps....................8W-44
Wheel Speed Sensors...................8W-35
Windshield Washer Pump Motor..........8W-53
Wipe/Wash Switch.....................8W-53
Wiper Motor..........................8W-53
8W - 02 - 2 8W - 02 COMPONENT INDEXPL
SPECIAL TOOLS (Continued)

Downloaded from www.Manualslib.com manuals search engine 8W-02 COMPONENT INDEX
GENERAL INFORMATION
INTRODUCTION
This section provides an alphabetical listing of all
the components covered in group 8W. For information
on system operation, refer to the appropriate section
of the wiring diagrams.
PL8W - 02 COMPONENT INDEX 8W - 02 - 3

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Downloaded from www.Manualslib.com manuals search engine 8W-10 POWER DISTRIBUTION
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION......................................................... 13
Component Page
A/C Compressor Clutch..................8W-10-9
A/C Compressor Clutch Relay.............8W-10-9
ABS Relay Box........................8W-10-7
Automatic Shut Down Relay.............8W-10-10
Battery.............................8W-10-4
Capacitor...........................8W-10-10
Circuit Breaker.......................8W-10-6
Clutch Pedal Position Switch.............8W-10-12
Data Link Connector...................8W-10-10
Dome Lamp..........................8W-10-8
Downstream Heated Oxygen Sensor........8W-10-10
Engine Starter Motor...................8W-10-5
Engine Starter Motor Relay............8W-10-5, 12
Engine Starter Motor Relay...............8W-10-5
Fog Lamp Relay......................8W-10-11
Fuel Injector No. 1....................8W-10-10
Fuel Injector No. 2....................8W-10-10
Fuel Injector No. 3....................8W-10-10
Fuel Injector No. 4....................8W-10-10
Fuel Pump Module....................8W-10-10
Fuel Pump Relay.....................8W-10-10
Fuse 1 (FB)..........................8W-10-6
Fuse 2 (PDC).......................8W-10-4, 5
Fuse 3 (PDC).......................8W-10-4, 6
Fuse 4 (FB)..........................8W-10-6
Fuse 5 (FB)..........................8W-10-6
Fuse 5 (PDC).......................8W-10-4, 7
Fuse 6 (FB)..........................8W-10-6
Fuse 7 (FB)..........................8W-10-6
Fuse 8 (FB)..........................8W-10-6
Fuse 8 (PDC).......................8W-10-4, 7
Fuse 10 (FB).........................8W-10-12
Fuse 10 (PDC)......................8W-10-4, 7
Fuse 11 (FB).........................8W-10-12
Fuse 11 (PDC)......................8W-10-4, 5
Fuse 12 (FB).........................8W-10-12
Fuse 13 (PDC)......................8W-10-4, 8
Fuse 14 (FB).........................8W-10-12
Fuse 15 (FB).........................8W-10-12
Fuse 16 (FB).........................8W-10-12
Fuse 16 (PDC)......................8W-10-4, 11
Fuse 18 (PDC)......................8W-10-4, 9
Fuse 20 (PDC)......................8W-10-4, 9
Fuse 21 (PDC)......................8W-10-4, 10
Component Page
Fuse 23 (PDC)......................8W-10-4, 10
Fuse 25 (PDC)......................8W-10-4, 9
Fuse Block........................8W-10-6, 12
G204...............................8W-10-5
Generator...........................8W-10-10
Glove Box Lamp And Switch..............8W-10-8
Headlamp Switch......................8W-10-6
Horn No. 1...........................8W-10-9
Horn No. 2...........................8W-10-9
Horn Relay..........................8W-10-9
Ignition Coil Pack.....................8W-10-10
Ignition Switch...................8W-10-5, 6, 12
Instrument Cluster...................8W-10-5, 8
Left Fog Lamp.......................8W-10-11
Left Visor/Vanity Lamps.................8W-10-8
Map/Reading Lamps....................8W-10-8
Noise Supressor......................8W-10-10
Power Distribution Center...............8W-10-10
Power Distribution Center . . 8W-10-4, 5, 6, 7, 8, 9, 10, 11
Powertrain Control Module..............8W-10-10
Radiator Fan Motor....................8W-10-7
Radio...............................8W-10-8
Rear Fog Lamp Switch.................8W-10-11
Rear Window Defogger Switch.............8W-10-7
Right Fog Lamp......................8W-10-11
Right Visor/Vanity Lamps................8W-10-8
S105..............................8W-10-10
S115 ..............................8W-10-11
S121..............................8W-10-10
S122..............................8W-10-10
S131...............................8W-10-9
S134..............................8W-10-10
S202...............................8W-10-5
S203...............................8W-10-8
S208...............................8W-10-5
S213...............................8W-10-6
S217...............................8W-10-6
S309...............................8W-10-8
Solid State Fan Relay...................8W-10-7
Stop Lamp Switch.....................8W-10-9
Trunk Lamp..........................8W-10-8
Turn Signal/Hazard Switch...............8W-10-9
Underhood Lamp......................8W-10-8
Upstream Heated Oxygen Sensor..........8W-10-10
8W - 10 - 2 8W - 10 POWER DISTRIBUTIONPL

Downloaded from www.Manualslib.com manuals search engine NOT
USEDFUEL
PUMP
RELAYAUTO
SHUT
DOWN
RELAYHORN
RELAY
A/C
CMPRSR
CLUTCH
RELAYENG
STRTR
MOTOR
RELAY
USEDNOTFUSE
25
13 FUSE
USEDNOT
FUSE
1823 FUSE
FUSE
21
20 FUSE
FUSE 10 FUSE 11
FUSE 2 FUSE 3
FUSE 5
FUSE 8
TOP OF
POWER DISTRIBUTION CENTER
PDC FUSE APPLICATION CHART
FUSE NO. AMPS CIRCUIT FUNCTION
240A A2 12PK/BK FUSED B+
A3 12RD/WT FUSED B+
A16 14GY 40A
3
FUSED B+
FUSED B+ 530A
A4 14BK/RD
A20 12RD/DG 30A
8
FUSED B+
A1 14RD 40A
10
FUSED B+
FUSED B+ 1130A
M1 18PK
FUSED B+ 1310A
M1 18PK
FUSED B+ A17 18RD/BKFUSED B+ F61 18WT/OR
20A
16
FUSED B+ 2010A
A14 16RD/WT
FUSED B+ 1810A
L9 18BK/WT
F32 18PK/DB 20A
21
FUSED B+
F32 18PK/DB 15A
23
FUSED B+15A
25
NOT
USED
F61 18WT/OR FUSED B+
8W - 10 - 2 8W-10 POWER DISTRIBUTIONPL-RHD
978W-1PLR01001