DODGE NEON 1999 Service Repair Manual

When the ignition switch is in the OFF position, or
when the radio frequency is being displayed, time
keeping is accurately maintained.
The procedure for setting the clock varies slightly
with each radio. The correct procedure is described in
the individual radio operating instructions. Refer to
the Owner's Manual supplied with the vehicle.
INSTRUMENT CLUSTER
There are two conventional instrument cluster
assemblies available. The clusters electronically drive
the speedometer, odometer, and gauges (Fig. 1) and
(Fig. 2).
GAUGES
All gauges in the electronic clusters are the analog
type gauges. When the ignition switch is moved to
the OFF position, the cluster drives each gauge to its
lowest position.
WARNING AND INDICATOR LAMPS
The instrument cluster has warning lamps and
indicators for the following systems:
²Airbag
²Anti-lock Brakes (ABS) if equipped
²Brake warning
²Charging System
²Door Ajar
²High beam indicator
²Low oil pressure
²Malfunction indicator (service engine soon) lamp
²Right and left turn signals.
²Seat belt warning
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM
For testing of this system refer to Group 8M,
Restraint Systems.
BRAKE SYSTEM WARNING LAMP TEST
The brake warning lamp illuminates when the
parking brake is applied with ignition switch turned
to the ON position. The same lamp will also illumi-
nate if one of the two service brake systems fail the
when brake pedal is applied.
To test the system:
²As the ignition switch is turned to the start posi-
tion the lamp should light.
²Turn ignition switch to the ON position and
apply the parking brake. The lamp should light.
If lamp fails to light inspect for:
²A burned out lamp
²Loose, corroded or damaged socket
²A damaged circuit board
²A broken or disconnected wire at the switch
²Defective switch
To test the service brake warning system, refer to
Group 5, Brakes, Hydraulic System Control Valves.
FOG LAMP SWITCH TEST
(1) Remove the fog lamp switch. Refer to the Rear
Window Defogger and/or Fog Lamp Switch Removal.
(2) Using two jumper wires, connect Pin 2 and Pin
4 of the switch to battery voltage.
(3) Using a test lamp, connect the test lamp to Pin
3 as shown in (Fig. 3). Refer to (Fig. 4) for fog lamp
switch circuit.
(4) Push the fog lamp switch button. The test lamp
and the LED indicator on the front of the switch
should illuminate.
(5) If either the LED or the test lamp fails to illu-
minate, replace the switch.Fig. 1 Instrument Cluster Without Tachometer
Fig. 2 Instrument Cluster With Tachometer
Fig. 3 Fog Lamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMSPL
DESCRIPTION AND OPERATION (Continued)

FUEL TANK SENDING UNIT TEST
Refer to Group 14, Fuel for test procedures.
HEADLAMP SWITCH TEST
(1) Remove the headlamp switch. Refer to Head-
lamp Switch Removal.
(2) Use a ohmmeter, and check continuity between
the terminals of the switch as shown in the Head-
lamp Switch Test (Fig. 5).
HEATER A/C BLOWER SWITCH TEST
(1) Remove Heater A/C control module. Refer to
Heater A/C Control Removal procedures.
(2) Use a ohmmeter, and check continuity between
the terminals of the switch as shown in the Blower
Switch Test (Fig. 6).
(3) If the switch fails any part of the continuity
test, other then Pin 1 to Pin 7, replace Heater A/C
Control. If no continuity between Pin 1 to Pin 7
check the lamps, replace if necessary.
HEATER BLOWER SWITCH TEST
(1) Remove heater control, refer to A/C Heater
Control Removal.
Fig. 4 Fog Lamp Switch Circuit
Fig. 5 Headlamp Switch Test
Fig. 6 Blower Switch Test
PLINSTRUMENT PANEL AND SYSTEMS 8E - 3
DIAGNOSIS AND TESTING (Continued)

(2) Use a ohmmeter, and check continuity between
the terminals of the switch as shown in the Heater
Blower Test (Fig. 7).
(3) If switch fails any part of the continuity test,
other then Pin 1 to Pin 7, replace heater control. If
no continuity between Pin 1 to Pin 7 check the
lamps, replace if necessary.
INSTRUMENT PANEL AND COMPONENTS
CAUTION: Disconnect the battery negative cable
before servicing the instrument panel or compo-
nents. When power is required for test purposes,
connect battery cable for test only. Disconnect the
battery negative cable after test and before continu-
ing service procedures.
LOW OIL PRESSURE WARNING LAMP TEST
The low oil pressure warning lamp will illuminate
when the ignition switch is turned to the ON position
without engine running. The lamp also illuminates if
the engine oil pressure drops below a safe oil pres-
sure level.
To test the system, turn the ignition switch to the
ON position. If the lamp fails to light, inspect for a
broken or disconnected wire at the oil pressure
switch, located at the front of the engine (Fig. 8). If
the wire at the connector checks good, pull the con-
nector loose from the switch and with a jumper wire,
ground the connector to the engine. With the ignition
switch turned to the ON position, check the warning
lamp. If the lamp still fails to light, inspect for aburned out lamp or disconnected socket in the clus-
ter.
MULTIPLE GAUGE INOPERATIVE TEST
Test speedometer, tachometer and other gauges for
malfunction:
(1) Remove the cluster. Refer to Cluster Removal
and Installation.
(2) Check for ignition voltage at Pin J1-5 of the
cluster wire harness connector (Fig. 9) and (Fig. 10).
Check for battery voltage at Pin J1-6 of the connec-
tor. If no voltage, repair as necessary.
(3) Check Pin J1-8 of the connector for continuity
to ground. If no ground, repair as necessary.
(4) If the voltage and ground are OK, and the pins
or the connectors are not distorted, replace the
printed circuit board.
(5) Install cluster.
INDIVIDUAL GAUGE INOPERATIVE
FUEL GAUGE
(1) Disconnect the fuel gauge sending unit.
Fig. 7 Heater Blower Switch Test
Fig. 8 Oil Pressure Switch
Fig. 9 Cluster Wire Harness Connector
8E - 4 INSTRUMENT PANEL AND SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

(2) Turn the ignition switch to the ON position.
The fuel gauge should be at its lowest position. Turn
the ignition switch OFF.
(3) Ground fuel gauge sending unit connector Pin
3. Refer to Group 8W, Wiring Diagrams. Turn igni-
tion switch to the ON position. The fuel gauge should
be at its highest position. Turn ignition switch OFF
then ON, after a sending unit signal change to dis-
able the cluster electronic gauge dampening mecha-
nism.
(a) If OK, check the fuel gauge sending unit con-
nector for proper connection. If the connections are
OK, refer to Group 14 Fuel System for Fuel Level
Sensor Diagnosis.
(b) If not OK, connect the sending unit. Remove
the cluster and check for an open or short in the
sending unit wiring. The sending unit will be less
than 1080 ohms and greater than 50 ohms depend-
ing upon fuel level. If the sending unit wiring is
open or a short circuit, repair as necessary.
(c) If the sending unit wiring is OK, replace the
gauge assembly. If the condition persists, replace
the cluster printed circuit board.
FUEL GAUGE INCORRECTLY INDICATES
EMPTY
The fuel system uses both the instrument cluster
and the Powertrain Control Module (PCM) to moni-
tor the fuel level sending unit. If the PCM fuel mon-
itoring circuits senses an open circuit, the increased
circuit resistance will causes a false fuel gauge empty
reading. Check for continuity between cluster wire
harness connector Pin J2-10 and Pin 23 of the PCM(Fig. 9) and (Fig. 11). If there is no continuity, repair
as necessary. If there is continuity, refer to Fuel
Gauge test.
LOW FUEL WARNING CIRCUIT
The low fuel warning lamp receives its signal from
the fuel gauge drive circuit. Due to production varia-
tions, the point where the lamp illuminates, may
vary from 1/16 to 3/16 mark on the fuel gauge. There
is a built in time delay before the lamp illuminates.
This prevents the lamp from going on and off under
various road conditions.
(1) Verify that the fuel gauge is operating properly.
(2) Check the low fuel warning lamp assembly.
(3) If the lamp still does not function under a low
fuel condition replace the printed circuit board.
TACHOMETER CIRCUIT
(1) Remove the cluster. Refer to Cluster Removal.
(2) Check for battery voltage at Pin J1-6 of the
cluster wire harness connector (Fig. 9).
(3) With the ignition switch in the ON position,
check for battery voltage at Pin J1-5 connector.
(4) Check Pin J1-8 of the connector for continuity
to ground.
(5) Check for tachometer signal from the Power-
train Control Module by connecting an AC DIGITAL
VOLTMETER to Pin J1-7 of the connector and
ground. A reading of at least 1.0 volt should be
present with the engine running.
(a) If the voltage is NOT within specification, go
to Step 6.
(b) If the voltage is within specification, go to
Step 7.
(6) If there is less than 1.0 volt at Pin J1-7 of the
connector, check for continuity between Pin J1-7 and
Pin 73 of the Powertrain Control Module connector
(Fig. 11). Also, check the connector at the Powertrain
Control Module for damaged pins or terminal push
outs.
(7) If the voltage is less than 1.0 volt at Pin J1-7 of
the connector and there is continuity between Pin
J1-7 and Pin 73 of the PCM connector, replace the
Powertrain Control Module.
Fig. 10 Cluster Connector
Fig. 11 Powertrain Control Module Pin Location
PLINSTRUMENT PANEL AND SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)

(8) If all tests performed test good, replace the dial
and gauge assembly.
(9) If the tachometer continues to be inoperative,
replace the print circuit board.
TEMPERATURE GAUGE
(1) Disconnect the coolant temperature sensor
(Fig. 12).
(2) Turn ignition switch ON. The temperature
gauge should be at its lowest position. Turn ignition
switch OFF.
(3) Ground temperature gauge sending unit con-
nector Pin 3. Refer to Group 8W, wiring Diagrams.
Turn ignition switch ON. The temperature gauge
should be at its highest position. After the seat belt
lamp goes out, the cluster should chime for about
eight seconds.
(a) If OK, check temperature sending unit con-
nector for proper connection. If connections are OK,
replace the sending unit.
(b) If not OK, and the high temperature chime
sounds but the gauge shows cold, replace the gauge
assembly. If gauge is still not working, replace the
printed circuit board.
SPEEDOMETER SYSTEM
The vehicle is equipped with a electronically driven
speedometer and odometer assemblies. A signal is
sent from a transmission-mounted vehicle speed sen-
sor to the speedometer circuitry through the wiring
harness.
SEAT BELT REMINDER SYSTEM TEST
For testing of this system refer to Group 8U,
Chime Warning/Reminder Systems.
SENDING UNIT
When a problem occurs with a cluster gauge check
for a defective sending unit or wiring. Do this before
disassembling the cluster.(1) Sending units and wiring can be checked by
grounding the connector leads at the sending unit in
the vehicle.
(2) With the ignition in the ON position, a
grounded input will cause the fuel or temperature
gauge to read at or above maximum.
SERVICE ENGINE SOON INDICATOR
Refer to Group 25, Emission Control Systems for
procedures.
VEHICLE SPEED SENSOR TEST
To test the vehicle speed sensor and related compo-
nents use a scan tool (DRB), and refer to the appro-
priate Powertrain Diagnostics Test Procedure
Manual.
REMOVAL AND INSTALLATION
ASH RECEIVER RETAINER AND LAMP
REMOVAL
(1) Open up and remove the ash receiver recepta-
cle.
(2) Remove the center bezel.
(3) Remove the two ash receiver retainer attaching
screws from the upper-rearward face and remove
retainer.
(4) For lamp replacement, remove the clamp and
lamp hood from the top of the retainer. Remove the
wiring clip at the forward edge of the retainer and
remove the lamp socket from the hood and replace
lamp.
INSTALLATION
For installation reverse the above procedures.
When installing the retainer ensure that the forward
tabs are inserted properly into the slots in the instru-
ment panel.
CENTER BEZEL
REMOVAL
(1) Open the ash receiver receptacle.
(2) Grasp the bezel and pull rearward disengaging
the clips.
INSTALLATION
For installation, reverse the above procedures.
CIGAR LIGHTER RECEPTACLE
REMOVAL
(1) Remove the cigar lighter element.
(2) Reach underneath the instrument panel
through the bottom access hole and disconnect the
cigar lighter receptacle wiring connectors.
Fig. 12 Engine Coolant Temperature Sensor
8E - 6 INSTRUMENT PANEL AND SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

(3) Press the cigar lighter receptacle from the
mounting ring by pushing it rearward from the back
side of the panel. Considerable force may be required
to disengage the receptacle. Remove the mounting
ring from the panel and discard. A new ring should
be used upon reinstallation to assure retention.
INSTALLATION
For installation, reverse the above procedures.
CLUSTER
CAUTION: Cluster MUST be stored in a face up posi-
tion or damage will occur to the gauge operation.
REMOVAL
(1) Disconnect the battery to ensure no DTCs are
generated.
(2) Remove the instrument panel top cover and
cluster bezel.
(3) Remove the four screws attaching cluster hous-
ing to the base panel.
(4) Pull the cluster rearward to disconnect from
base panel.
(5) Remove the cluster assembly.
INSTALLATION
For installation, reverse the above procedures.
CLUSTER LAMP
The Instrument Cluster illumination Lamps location
are shown in (Fig. 13). The cluster is viewed from the
rear. To replace lamp(s), the cluster must be removed.
Refer to Cluster Removal and Installation procedure.
CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
(1) Remove the cluster, refer to Cluster Removal.
(2) Remove the attaching screws and rear cover
(Fig. 14). The bottom screws attaching lens to hous-
ing can be accessed without removing foam pad.
Fig. 13 Instrument Cluster Illumination Lamps
Fig. 14 Cluster Assembly
PLINSTRUMENT PANEL AND SYSTEMS 8E - 7
REMOVAL AND INSTALLATION (Continued)

(3) Disconnect the odometer connector and remove
eight attaching screws that attach the printed circuit
board and housing (Fig. 15).
(4) Carefully remove printed circuit board from the
cluster.
INSTALLATION
For installation, reverse the above procedures.
Carefully place board on the cluster and ensure that
the odometer connector is placed through the board.
Gently press board on cluster with a slight rocking
motion to ensure pins on gauges line up.
DOME LENS/LAMP
REMOVAL
Pry either the forward or rearward edge of the lens
away from the retainer and replace the lamp.
INSTALLATION
For installation, snap lens into retainer.
FLOOR CONSOLE
REMOVAL
(1) Remove the MTX shifter knob only.
(2) Remove the attaching screws from each side of
the cup holder.
(a) Non-armrest console. Remove the two screws
from the rear of the console (Fig. 16).
(b) Armrest console. Remove the four screws in
the console bin.
(3) Pull the parking brake lever up all the way.
(4) Lift the console at the rear and guide it out
from under the instrument panel.
INSTALLATION
For installation, reverse the above procedures.
GAUGE
REMOVAL
(1) Remove the cluster. Refer to Cluster Removal.
(2) Remove the attaching screws PC board cover
(Fig. 15). The bottom screws attaching lens to hous-
ing can be accessed without removing the foam pad.
(3) Disconnect the odometer connector.
(4) Remove the lens attaching screws and remove
the lens.
(5) Carefully pry out the dial and gauge assembly.
INSTALLATION
For installation, reverse the above procedures.
(1) When handling or storing the cluster ensure
that overlays are not damaged. Set the cluster in the
face up position or the gauge operation will be dam-
aged.
(2) The gauges are replaced as an dial and gauge
assembly.
GLOVE BOX DOOR/BIN
REMOVAL
(1) Disconnect battery negative cable and isolate it
or remove fuse 12 prior to removing the switch, or
the wires may short to ground.
(2) Remove the screws along the bottom of glove
box door.
(3) Open the glove box and push the glove box
sides inward allowing the door bumpers to clear and
box to tip forward.
(4) Pull the glove box door/bin rearward and
remove from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Fig. 15 Printed Circuit Board
Fig. 16 Floor Console with Transmission Range
Indicator
8E - 8 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

GLOVE BOX SWITCH/LAMP
REMOVAL
(1) Disconnect battery negative cable and isolate it
or remove fuse 12 prior to removing the switch, or
wires may short to ground.
(2) Open the glove box and push the glove box
sides inward allowing the door bumpers to clear and
the box to tip rearward.
(3) Reach inside the opening and squeeze the
lamp/switch retainers until they are disengage.
(4) Pull the switch/lamp rearward and remove it.
Replace the lamp. To replace the switch disconnect
wire and replace the switch.
INSTALLATION
For installation, reverse the above procedures.
HEADLAMP SWITCH
REMOVAL
(1) Remove the steering column cover and liner.
(2) Remove the three screws securing headlamp
switch mounting plate to the instrument panel (Fig.
17).
(3) Pull the headlamp switch and mounting plate
rearward from the instrument panel opening.
(4) Disconnect both the nine way and the ground
wiring connectors from the switch.
(5) Remove the switch knob by depressing the
release button on the bottom on the switch and pull-
ing out knob from switch.
(6) Snap headlamp switch bezel out of mounting
plate to gain access to the mounting plate retaining
nut.
(7) Remove the headlamp switch, mounting plate
retaining nut and separate switch from mounting
plate.
INSTALLATION
For installation, reverse the above procedures.
HEATER A/C CONTROL
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick (special tool #C-4755), gently
pry up on the top cover and cluster bezel to remove
(Fig. 19).
(3) Open the ash receiver.
(4) Using a trim stick (special tool #C-4755), gently
pry out on the center bezel and remove.
(5) Remove the six attaching screws across the for-
ward portion of the right upper trim panel. Then pull
the panel rearward to disengage the three locator
pins and remove.(6) Reach in and disconnect the wiring connector(s)
for the rear window defogger and/or fog lamp
switch(s) as required.
(7) If equipped with RKE, remove the two screws
retaining the module and lay over the instrument
cluster.
(8) Gently pull on the center A/C outlet duct to
remove.
(9) Remove three attaching screws at corners of
the control (Fig. 18), two front retaining and one
retaining from the top rear.
(10) Pull the control rearward and disconnect the
wiring connector.
(11) Using a screwdriver, disengage the cable
attachment clips.
INSTALLATION
For installation, reverse the above procedures.
Fig. 17 Headlamp Switch
Fig. 18 Heater A/C Control
PLINSTRUMENT PANEL AND SYSTEMS 8E - 9
REMOVAL AND INSTALLATION (Continued)

HEATER A/C CONTROL BLOWER SWITCH
The switch is not serviced, replace heater A/C con-
trol. Refer to the Heater A/C Control Removal and
Installation.
HEATER A/C CONTROL LAMP
REMOVAL
(1) Remove the Heater A/C Control. Refer to the
Heater A/C Control Removal.
(2) Remove the two center knobs by pulling the
knob rearward.
(3) Replace the lamp.
INSTALLATION
For installation, reverse the above procedures.
HEATER CONTROL BLOWER SWITCH
The switch is not serviced, replace the heater con-
trol. Refer to the A/C Heater Control Removal and
Installation.
IGNITION KEY LAMP
REMOVAL
(1) Remove the steering column cover. Refer to
Steering Column Cover Removal.
(2) Disconnect the lamp hood from the base panel.
(3) Remove the lamp socket from hood and replace
the lamp.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT PANEL
REMOVAL
CAUTION: Disconnect battery negative cable, in
engine compartment, before servicing instrument
panel.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the floor console. Refer to Floor Con-
sole Removal.
(3) Remove the right and left cowl side trim pan-
els (Fig. 19).
(4) Remove the steering column cover and liner.
(5) Remove the top cover and cluster bezel assem-
bly.
(6) Remove the right and left trim panel.
(7) Remove the defroster upper duct by lifting it
up.
(8) Remove the center outlet duct by pulling rear-
ward.(9) Disconnect the Heater A/C Control, by remov-
ing the control cables clips with a screwdriver and
remove the wire connector.
CAUTION: Lock the steering wheel in the straight
ahead position. This will prevent clockspring dam-
age when the steering wheel rotates freely.
(10) Disconnect the steering column at the bottom
slap together joint.
(11) Disconnect the ATX shifter interlock cable at
the shifter, if equipped.
(12) Disconnect the instrument panel wiring as
required.
(13) Remove the four attaching screws at the cen-
ter floor pan bracket (Fig. 20).
(14) Remove the four attaching screws at steering
column.
(15) Remove the four cowl top nuts.
(16) Remove the attaching screws from the left
and right lower cowl side bracket (Fig. 21).
(17) Remove the two attaching screws from the left
upper cowl side and one from the right upper cowl
side.
(18) Pull the instrument panel rearward away
from the dash/plenum.
(19) Remove the instrument panel from vehicle.
INSTALLATION
For installation, reverse the above procedures.
LEFT TRIM PANEL
REMOVAL
(1) Remove the top cover and cluster bezel (Fig.
19).
(2) Remove the steering column cover.
(3) Remove the two attaching screws along the
bottom and the one at the top of the trim panel and
pull rearward to remove.
INSTALLATION
For installation, reverse the above procedures.
ODOMETER
REMOVAL
(1) Remove the instrument panel top cover and
cluster bezel.
(2) Remove the four screws attaching cluster to
instrument panel (Fig. 22).
(3) Remove the cluster.
(4) Remove the screws attaching PC board cover to
cluster.
(5) Disconnect the odometer connector from the
printed circuit board.
8E - 10 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

Fig. 19 Instrument Panel Assembly
PLINSTRUMENT PANEL AND SYSTEMS 8E - 11
REMOVAL AND INSTALLATION (Continued)