brake sensor DODGE NEON 1999 Service Owner's Manual

(2) Unplug the pump motor wiring harness (Fig.
33) from the CAB.
(3) Remove the 4 bolts (Fig. 34) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 35).
INSTALL
(1) Install the CAB (Fig. 35) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 34)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 33).
(4) Install the ICU. Refer to ABS Integrated Con-
trol Unit in the Removal And Installation Section in
this group of the service manual for the Installation
procedure.
(5) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.(6) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
FRONT WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Unplug speed sensor cable connector (Fig. 36)
from vehicle wiring harness. Remove clip (Fig. 36)
attaching speed sensor cable connector to vehicle
body.
(4) Remove wheel speed sensor head to steering
knuckle attaching bolt (Fig. 37).
(5) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion,
DO NOT USE PLIERS ON SENSOR HEAD.Use
a hammer and a punch and tap edge of sensor ear,
rocking the sensor side to side until free.
(6) Remove the speed sensor cable assembly grom-
mets from the retaining bracket (Fig. 38). Remove
speed sensor cable routing clip from the frame of the
vehicle (Fig. 38).
Fig. 33 Pump Motor To CAB Wiring Harness
Fig. 34 CAB Attaching Bolts
Fig. 35 Remove/Install CAB
PLBRAKES 5 - 87
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Connect the wheel speed sensor cable connector
to the vehicle wiring harness (Fig. 36).
(2) Install the speed sensor cable assembly grom-
mets into the retaining bracket (Fig. 38). Installspeed sensor cable routing clip onto the frame of the
vehicle (Fig. 38).
(3) Install wheel speed sensor to steering knuckle
attaching screw (Fig. 37). Torque the attaching screw
to 7 N´m (60 in. lbs.)
(4) Install the wheel and tire assembly on vehicle.
(5) Road test vehicle to ensure proper operation of
the base and ABS systems.
REAR WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel from the vehicle.
(3) Unplug speed sensor cable connector from vehi-
cle wiring harness (Fig. 39). Remove clip (Fig. 39)
attaching speed sensor cable connector to vehicle
body.
(4) Remove the speed sensor cable routing bracket
from under rear brake flex hose mounting bracket.
Then remove the speed sensor cable from the routing
clips on the rear brake flex hose and chassis brake
tube.
(5) Remove bolt (Fig. 40) attaching the rear wheel
speed sensor to the disc brake adapter. Then remove
Fig. 36 Speed Sensor Cable To Wiring Harness
Connection
Fig. 37 Front Wheel Speed Sensor Attaching Bolt
Fig. 38 Front Wheel Speed Sensor Cable Routing
Fig. 39 Rear Speed Sensor Connection To Vehicle
Wiring Harness
5 - 88 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

bolt attaching speed sensor cable routing bracket to
rear strut assembly (Fig. 40).
(6) Remove speed sensor head from the disc brake
adapter. If the speed sensor head has seized in the
adapter, DO NOT USE PLIERS ON SENSOR HEAD.
INSTALL
(1) Install wheel speed sensor head into disc brake
adapter (Fig. 40).
(2) Install wheel speed sensor attaching bolt (Fig.
40). Tighten the attaching bolt to a torque of 7 N´m
(60 in. lbs.)
(3) Install the brake flex hose and wheel speed
sensor cable routing bracket on the rear strut
bracket (Fig. 40).
(4) Install wheel speed sensor cable into the rout-
ing clips on the rear brake flex hose and chassis
brake tube.
(5) Plug speed sensor cable connector into vehicle
wiring harness (Fig. 39). Install clip (Fig. 39) attach-
ing speed sensor cable connector to vehicle body.
(6) Install the tire and wheel assembly on vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS systems.
SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
The total indicator runout allowed for both the
front and rear tone wheel measured using a dial indi-
cator is 0.25 mm (.009 in.).
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE
FRONT WHEEL
Minimum Clearance 0.17 mm (0.007 in.)
Maxamum Clearance 1.80 mm (0.072 in.)
REAR WHEEL
Minimum Clearance 0.37 mm (0.015 in.)
Maxamum Clearance 1.50 mm (0.059 in.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To HCU
At HCU Ports.............21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
MASTER CYLINDER:
To Vacuum Booster
Mounting Nut............28N´m(250 in. lbs.)
BRAKE BOOSTER:
To Dash Panel Mounting Nuts . .28 N´m (250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate
Mounting Bolts............13N´m(115in.lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
REAR DISC BRAKE ADAPTER:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts.............22N´m(192 in. lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
To Mounting Bracket Bolts.....28N´m(250 in. lbs.)
Bracket To Frame Rail
Mounting Bolt (Top)........18N´m(160 in. lbs.)
Bracket To Frame Rail
Mounting Bolts (Side)......22N´m(200 in. lbs.)
PARKING BRAKE:
Lever Mounting Nuts.........28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Knuckle Retaining Nut.....217 N´m (160 ft. lbs.)
WHEEL:
Stud Lug Nut........109±150 N´m (80±110 ft. lbs.)
Fig. 40 Speed Sensor Head Mounting And Cable
Routing
PLBRAKES 5 - 89
REMOVAL AND INSTALLATION (Continued)

performed at each (- ground) connection in this cir-
cuit to locate the excessive resistance.
(7) Testing (+ positive) circuitry:
(a) Touch the positive lead of voltmeter directly
to battery negativePOST.
(b) Touch the negative lead of voltmeter to the
ground terminal stud on the generator case (not
the terminal mounting nut). Voltage should be no
higher than 0.3 volts. If voltage is higher than 0.3
volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. If voltage is
now below 0.3 volts, look for dirty, loose or poor
connection at this point. A voltage drop test may be
performed at each (+ positive) connection in this
circuit to locate the excessive resistance. This test
can also be performed between the generator case
and the engine. If test voltage is higher than 0.3
volts, check for corrosion at generator mounting
points or loose generator mounting.
CURRENT OUTPUT TEST
The current output test will determine if the
charging system can deliver its minimum test cur-
rent (amperage) output. Refer to the Specifications
section at the end of this group for minimum test
current (amperage) requirements.
The first part of this test will determine the com-
bined amperage output of both the generator and the
Electronic Voltage Regulator (EVR) circuitry.
PREPARATION
(1) Determine if any Diagnostic Trouble Codes
(DTC) exist. To determine a DTC, refer to On-Board
Diagnostics in this group. For repair, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual.
(2) Before starting test, make sure battery is in
good condition and is fully-charged. See Group 8A,
Battery for more information.
(3) Check condition of battery cables at battery.
Clean if necessary.
(4) Perform the Voltage Drop Test. This will
ensure clean and tight generator/battery electrical
connections.
(5) Be sure the generator drive belt is properly
tensioned. Refer to Group 7, Cooling System for
information.
(6) A volt/amp tester equipped with both a battery
load control (carbon pile rheostat) and an inductive-
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied
with tester. When using a tester equipped with an
inductive-type clamp, removal of wiring at the gener-
ator will not be necessary.
(7) Start the engine and allow it to reach operating
temperature.
(8) Shut engine off.(9) Turn off all electrical accessories and all vehicle
lighting.
(10) Connect the volt/amp tester leads to the bat-
tery. Be sure the carbon pile rheostat control is in the
OPEN or OFF position before connecting leads. See
Load Test in Group 8A, Battery for more information.
Also refer to the operating instructions supplied with
test equipment.
(11) Connect the inductive clamp (ammeter probe).
Refer to the operating instructions supplied with test
equipment.
(12) If volt/amp tester is not equipped with an
engine tachometer, connect a separate tachometer to
the engine.
TEST
(1) Perform the previous test Preparation.
(2) Fully engage the parking brake.
(3) Start engine.
(4) Bring engine speed to 2500 rpm.
(5) With engine speed held at 2500 rpm, slowly
adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment.On
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment.
(6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera-
tor Ratings chart. This can be found in the Specifica-
tions section at the end of this group. A label stating
a part reference number is attached to the generator
case. On some engines this label may be located on
the bottom of the case. Compare this reference num-
ber to the Generator Ratings chart.
(7) Rotate the load control to the OFF position.
(8) Continue holding engine speed at 2500. If EVR
circuitry is OK, amperage should drop below 15±20
amps. With all electrical accessories and vehicle
lighting off, this could take several minutes of engine
operation. If amperage did not drop, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual for testing.
(9) Remove volt/amp tester.
If minimum amperage could not be met, refer to
the appropriate Powertrain Diagnostic Procedures
manual for testing.
BATTERY TEMPERATURE SENSOR
To perform a complete test of this sensor and its
circuitry, refer to the appropriate Powertrain Diag-
nostic Procedures manual. To test the sensor only,
refer to the following:
(1) The sensor is located under the battery and is
attached to the battery tray (Fig. 5). A two-wire pig-
8C - 8 CHARGING SYSTEMPL
DIAGNOSIS AND TESTING (Continued)

train Control Module (PCM) with an input signal
(voltage). The signal represents throttle blade posi-
tion. As the position of the throttle blade changes,
the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade
position. The TPS output voltage to the PCM varies
from approximately 0.38 volts to 1.2 volts at mini-
mum throttle opening (idle) to a maximum of 3.1
volts to 4.4 volts at wide open throttle.
Along with inputs from other sensors, the PCM
uses the TPS input to determine current engine oper-
ating conditions. The PCM also adjusts fuel injector
pulse width and ignition timing based on these
inputs.
IGNITION SWITCH
In the RUN position, the ignition switch connects
power from the Power Distribution Center (PDC) to a
30 amp fuse in the fuse block, back to a bus bar in
the PDC. The bus bar feeds circuits for the Power-
train Control Module (PCM), duty cycle purge sole-
noid, EGR solenoid, and ABS system. The bus bar in
the PDC feeds the coil side of the radiator fan relay,
A/C compressor clutch relay, and the fuel pump relay.
It also feeds the Airbag Control Module (ACM)
LOCK KEY CYLINDER
The lock cylinder is inserted in the end of the
housing opposite the ignition switch. The ignition key
rotates the cylinder to 5 different detents (Fig. 16):
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Off, Run or Start position. In addi-
tion, the operator cannot rotate the key to the lock
position unless the shifter is in the park position. On
vehicles equipped with floor shift refer to Group 21 -
Transaxle for Automatic Transmission Shifter/Igni-
tion Interlock.
DIAGNOSIS AND TESTING
TESTING FOR SPARK AT COILÐ2.0/2.4L
WARNING: THE DIRECT IGNITION SYSTEMS GEN-
ERATES APPROXIMATELY 40,000 VOLTS. PER-
SONAL INJURY COULD RESULT FROM CONTACT
WITH THIS SYSTEM.
The coil pack contains independent coils. Each coil
must be checked individually.
CAUTION: Spark plug wire damage may occur if
the spark plug is moved more than 1/4 inch away
from the engine ground.
CAUTION: Do not leave any one spark plug cable
disconnected any longer than 30 seconds or possi-
ble heat damage to catalytic converter will occur.
CAUTION: Test must be performed at idle and in
park only with the parking brake on.
NOTE: New isolated engine valve cover may not
provide adequate ground. Use engine block as
engine ground.
Fig. 15 MAP/IAT sensorÐDOHCFig. 16 Ignition Lock Cylinder Detents
PLIGNITION SYSTEM 8D - 7
DESCRIPTION AND OPERATION (Continued)

(2) Remove the air cleaner inlet tube.
(3) Disconnect electrical connectors from engine
coolant sensor and camshaft position sensor.
(4) Remove brake booster hose and electrical con-
nector from holders on end of cylinder head cover.
(5) Remove camshaft position sensor mounting
screws. Remove sensor.
(6) Loosen screw attaching target magnet to rear
of camshaft (Fig. 33).
INSTALLATION
The target magnet has two locating dowels that fit
into machined locating holes in end of the camshaft.
(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3.4 N´m (30 in. lbs.)
torque.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 9 N´m (80 in. lbs.) torque.
(3) Place brake booster hose and electrical harness
in holders on end of valve cover.
(4) Attach electrical connectors to coolant tempera-
ture sensor and camshaft position sensor.(5) Install air cleaner inlet tube and filtered air
tube.
CAMSHAFT POSITION SENSORÐDOHC
The camshaft position sensor is mounted to the
rear of the cylinder head (Fig. 34).
REMOVAL
(1) Remove filtered air tube from the throttle body
and air cleaner housing.
(2) Disconnect electrical connector from camshaft
position sensor.
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft (Fig. 35).
INSTALLATION
The target magnet has locating dowels that fit into
machined locating holes in the end of the camshaft
(Fig. 36).
Fig. 32 Camshaft Position Sensor LocationÐSOHC
Fig. 33 Target Magnet Removal/Installation
Fig. 34 Camshaft Position Sensor LocationÐDOHC
Fig. 35 Target Magnet Removal/Installation
8D - 14 IGNITION SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
DOME LAMP............................ 1
ELECTRONIC DIGITAL CLOCK.............. 1
INSTRUMENT CLUSTER................... 2
WARNING AND INDICATOR LAMPS......... 2
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM............... 2
BRAKE SYSTEM WARNING LAMP TEST...... 2
FOG LAMP SWITCH TEST................. 2
FUEL TANK SENDING UNIT TEST........... 3
HEADLAMP SWITCH TEST................. 3
HEATER A/C BLOWER SWITCH TEST........ 3
HEATER BLOWER SWITCH TEST............ 3
INDIVIDUAL GAUGE INOPERATIVE.......... 4
INSTRUMENT PANEL AND COMPONENTS.... 4
LOW OIL PRESSURE WARNING LAMP TEST . . 4
MULTIPLE GAUGE INOPERATIVE TEST....... 4
SEAT BELT REMINDER SYSTEM TEST....... 6
SENDING UNIT......................... 6
SERVICE ENGINE SOON INDICATOR......... 6
VEHICLE SPEED SENSOR TEST............. 6
REMOVAL AND INSTALLATION
ASH RECEIVER RETAINER AND LAMP....... 6
CENTER BEZEL.......................... 6
CIGAR LIGHTER RECEPTACLE.............. 6
CLUSTER LAMP......................... 7
CLUSTER PRINTED CIRCUIT BOARD........ 7CLUSTER.............................. 7
DOME LENS/LAMP....................... 8
FLOOR CONSOLE........................ 8
GAUGE................................ 8
GLOVE BOX DOOR/BIN................... 8
GLOVE BOX SWITCH/LAMP................ 9
HEADLAMP SWITCH..................... 9
HEATER A/C CONTROL BLOWER SWITCH . . . 10
HEATER A/C CONTROL LAMP............ 10
HEATER A/C CONTROL................... 9
HEATER CONTROL BLOWER SWITCH....... 10
IGNITION KEY LAMP.................... 10
INSTRUMENT PANEL.................... 10
LEFT TRIM PANEL...................... 10
ODOMETER............................ 10
RADIO................................ 12
REAR WINDOW DEFOGGER AND/OR FOG
LAMP SWITCH....................... 12
RIGHT TRIM PANEL..................... 12
SHIFTER KNOB......................... 13
STEERING COLUMN COVER LINER......... 13
STEERING COLUMN COVER.............. 13
STEERING COLUMN SHROUDS............ 13
TOP COVER AND CLUSTER BEZEL
REMOVAL........................... 14
TRANSMISSION RANGE INDICATOR LAMP . . 14
TRUNK LAMP/LENS..................... 14
VEHICLE SPEED SENSOR................ 14
GENERAL INFORMATION
INTRODUCTION
The purpose of the dash gauges and indicator
lamps is to keep the driver informed about the oper-
ating condition of the vehicle. If an abnormal condi-
tion occurs, the driver is informed by indicator lamp.
The driver can seek service before damage occurs.
Indicator lamps use ON/OFF switch functions for
operation, while gauges use a sending unit or sensor.
DESCRIPTION AND OPERATION
DOME LAMP
The Dome Lamp operates when a door is open or
when the headlamp switch is placed in courtesy posi-
tion.
ELECTRONIC DIGITAL CLOCK
The electronic digital clock is in the radio. The
clock and radio each use the display panel built into
the radio. A digital readout indicates the time in
hours and minutes whenever the ignition switch is in
the ON or ACC position.
PLINSTRUMENT PANEL AND SYSTEMS 8E - 1

(2) Lift up the top cover and cluster bezel until the
clips disengage and separate to provide clearance
(Fig. 25).
(3) Rotate the ignition key cylinder to run/on posi-
tion. Insert a screw driver into the access hole at the
bottom of lower shroud to release the ignition key
cylinder.
(4) Pull out the ignition key cylinder.
(5) Remove the three lower to upper shroud
attaching screws through the bottom of the lower
shroud.
(6) Separate the upper and lower shrouds.
INSTALLATION
For installation, reverse the above procedures.
TOP COVER AND CLUSTER BEZEL REMOVAL
REMOVAL
(1) Use care not to scratch the panel. Lift up on
the bottom outer areas of the cluster bezel and alongthe rearward edge of the top cover to disengage the
clips (Fig. 24).
(2) Pull the top cover and cluster bezel rearward
until the forward pins disengage from the instrument
panel.
INSTALLATION
For installation, reverse the above procedures,
making sure that the forward pins engage the index
holes in the instrument panel. Position spring clips
in instrument panel and push firmly until seated.
TRANSMISSION RANGE INDICATOR LAMP
REMOVAL
(1) Raise the floor console (Fig. 16).
(2) Remove the attaching screw from each of the
two forward cup holders of the floor console. Remove
the screws at the rear of the console or inside of the
armrest console bin.
(3) Pull the parking brake lever all the way up.
(4) Lift the floor console at the rear high enough to
gain access to the lamp and socket.
(5) Remove the indicator lamp socket from bezel to
replace the lamp.
INSTALLATION
For installation, reverse the above procedures.
TRUNK LAMP/LENS
REMOVAL
The trunk lamp snaps into the rear shelf panel
reinforcement under/below the package shelf.
(1) Remove the socket assembly by reaching up
above the sheet metal. Push the snap inward and
downward and remove the assembly.
(2) Remove the lamp from socket and pull the
socket from the lens. Replace as necessary.
INSTALLATION
For installation, reverse the above procedures.
VEHICLE SPEED SENSOR
For Vehicle Soeed Sensor Removal and Installa-
tion, refer to Group 14±Fuel Systems for service
procedures.
Fig. 25 Upper/Lower Shroud
8E - 14 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
STOP LAMP SWITCH
Vehicles equipped with the speed control option use
a dual function stop lamp switch. The switch is
mounted on the brake pedal mounting bracket under
the instrument panel. The PCM monitors the state of
the dual function stop lamp switch. Refer to Group 5,
Brakes for more information on stop lamp switch ser-
vice and adjustment procedures.
SERVO CABLE
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage. This cable causes the
throttle control linkage to open or close the throttle
valve in response to movement of the vacuum servo
diaphragm.
POWERTRAIN CONTROL MODULE
The speed control electronic control circuitry is
integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compart-
ment. The PCM speed control functions are moni-
tored by the On-Board Diagnostics (OBD). All OBD-
sensed systems are monitored by the PCM. Each
monitored circuit is assigned a Diagnostic Trouble
Code (DTC). The PCM will store a DTC in electronic
memory for any failure it detects. See On-Board
Diagnostic Tests in this group for more information.
The PCM cannot be repaired and must be replaced if
faulty.
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE ORIGINAL VEHICLES MILEAGE. IF THIS
STEP IS NOT DONE A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
VACUUM RESERVOIR
The reservoir contains a one-way check valve to
trap engine vacuum in the reservoir. When engine
vacuum drops, as in climbing a grade while driving,
the reservoir supplies the vacuum needed to main-
tain proper speed control operation. The vacuum res-
ervoir cannot be repaired and must be replaced if
faulty.
VEHICLE SPEED AND DISTANCE
The 4 speed automatic Transmission Control Mod-
ule (TCM) supplies the speed input to the PCM. The
PCM determines acceleration rates. The speed con-
trol software in the PCM uses vehicle speed and
acceleration to control to the set speed.Vehicles with a 3 speed automatic or manual trans-
mission have a vehicle speed sensor (VSS) mounted
to an adapter near the transmission output shaft.
The sensor is driven through the adapter by a speed-
ometer pinion gear. The VSS pulse signal is moni-
tored by the PCM to determine vehicle speed and to
maintain speed control set speed. Refer to the appro-
priate Powertrain Diagnostic Procedures manual for
diagnosis and testing of this component. Refer to
group 14, Fuel System for Removal/Installation
DIAGNOSIS AND TESTING
ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to Group 8E,
Instrument Panel and Gauges for speedometer diag-
nosis.
If a road test verifies a surge following a set and
the speedometer operates properly see ªOvershoot/
Undershoot on speed control setº.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures service manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
PLVEHICLE SPEED CONTROL SYSTEM 8H - 3
DESCRIPTION AND OPERATION (Continued)

(c) If continuity is OK between cavity 62 and
cavity 1, repair open circuit between cavity 2 of the
stop lamp switch connector and ground.
(6) Using an ohmmeter, check continuity from cav-
ity 76 on PCM connector to ground with the trans-
mission in park or neutral. If no continuity, test TRS/
Park-Neutral switch and switch wiring
(7) Turn speed control and ignition switch OFF.
(8) Unplug the BLACK 40-way connector from the
Powertrain Control Module (PCM)
(9) Using an ohmmeter, check continuity from cav-
ity 3 of servo connector to cavity 5 on the PCM con-
nector.
(a) If continuity is OK, replace PCM. Check cir-
cuit for short to ground before replacing PCM.
(b) If no continuity, remove stop lamp switch
and conduct Stop Lamp Switch Test. If test fails,
adjust or replace as necessary.
(c) If switch passes, measure continuity from
cavity 4 of stop lamp switch connector to cavity 3
of servo connector. Repair open circuit if necessary.
(d) If continuity is OK, measure continuity from
cavity 3 of stop lamp switch to cavity 5 of PCM
connector. Repair open circuit as necessary.
(e) Install PCM connectors onto PCM and speed
control servo connector to servo.
VACUUM SUPPLY TEST
(1) Disconnect vacuum hose at the servo and
install a vacuum gauge in the hose (Fig. 9).
(2) Start engine and observe gauge at idle. Vac-
uum gauge should read at least ten inches of mer-
cury. Shut off engine, the vacuum should continue to
hold 10 inches of mercury.
(3) If vacuum does not meet this requirement,
check and correct the following vacuum leaks in the
vacuum lines, check valve, vacuum reservoir or poor
engine performance.
VEHICLE SPEED SENSOR
For diagnosis and testing of the Vehicle Speed Sen-
sor (VSS), refer to the appropriate Powertrain Diag-
nostic Procedures service manual. Also refer to the
DRB scan tool.
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
REMOVAL
(1) Disconnect electrical connector from servo.
(2) Disconnect vacuum hoses from servo
(3) Remove 2 nuts retaining cable to servo.
(4) Remove hair pin holding cable to servo.
INSTALLATION
(1) Install hairpin to cable at servo.
(2) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(3) Connect electrical connector to servo.
(4) Connect vacuum hose to servo
SPEED CONTROL SWITCH
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module (Fig. 1).
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
REMOVAL
(1) Turn off ignition.
(2) Remove two screws from side of each switch.
(3) Rock switch away from airbag and steering
wheel.
(4) Disconnect two-way electrical connector.
(5) Repeat for the other switch.
INSTALLATION
For installation reverse above procedures.
STOP LAMP SWITCH
REMOVAL
Remove the switch from the bracket by depressing
the brake pedal and rotating the switch in a counter-
clockwise direction approximately 30 degrees. Pull
the switch rearward and remove from bracket. Dis-
connect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable
switch plunger by pulling on the plunger head until
Fig. 9 Vacuum Gauge TestÐTypical
8H - 8 VEHICLE SPEED CONTROL SYSTEMPL
DIAGNOSIS AND TESTING (Continued)