ignition DODGE NEON 1999 Service Owner's Manual

NOTE: BLACK OR DARK=0to75%state-of-charge
The battery is INADEQUATELY charged and must
be charged until green dot is visible, (12.4 volts or
greater) before the battery is tested or returned to
use. Refer to Causes of Battery Discharging in this
Group for more information.
NOTE: CLEAR COLOR = Replace Battery
WARNING: DO NOT CHARGE, ASSIST BOOST,
LOAD TEST, OR ADD WATER TO THE BATTERY
WHEN CLEAR COLOR DOT IS VISIBLE. PERSONAL
INJURY MAY OCCUR.
A clear color dot shows electrolyte level in battery
is below the test indicator (Fig. 1). Water cannot be
added to a maintenance free battery. The battery
must be replaced. A low electrolyte level may be
caused by an over charging condition. Refer to Gen-
erator Test Procedures on Vehicle.
CAUSES OF BATTERY DISCHARGING
It is normal to have a small 5 to 25 milliamperes
continuous electrical draw from the battery. This
draw will take place with the ignition in the OFF
position, and the courtesy, dome, storage compart-
ments, and engine compartment lights OFF. The con-
tinuous draw is due to various electronic features or
accessories that require electrical current with the
ignition OFF to function properly. When a vehicle is
not used over an extended period of approximately 20
days the IOD fuse should be pulled. The fuse is
located in the power distribution center. removal of
this fuse will reduce the level of battery discharge.
Refer to the Battery Diagnosis and Testing Table for
proper diagnosis.
ABNORMAL BATTERY DISCHARGING
²Corroded battery posts, cables or terminals.
²Loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system due to equipment or accessories
installed after delivery.
²Slow driving speeds in heavy traffic conditions
or prolonged idling with high-amperage electrical
systems in use.
²Defective electrical circuit or component causing
excess Ignition Off Draw (IOD). Refer to Battery
Ignition Off Draw (IOD).
²Defective charging system.
²Defective battery.
BATTERY IGNITION OFF DRAW (IOD)
High current draw on the battery with the ignition
OFF will discharge a battery. After a dead battery is
recharged, the vehicle ignition off draw (IOD) shouldbe checked. To determine if a high current draw con-
dition exists first check the vehicle with a test lamp.
(1) Verify that all electrical accessories are OFF.
²Remove key from ignition switch
²Turn off all lights
²Trunk lid is closed
²Engine compartment hood lamp is disconnected
or lamp removed
²Glove box door is closed
²Sun visor vanity lights are OFF
²All doors are closed
²Allow the ignition key lamp system to time out
in approximately 30 seconds, if equipped.
(2) Disconnect battery negative cable (Fig. 4).
(3) Connect a 12 Volt test lamp, with a cold resis-
tance of 5-7 ohms, between the battery negative cable
clamp and the negative post (Fig. 5). If test lamp
goes out system is OK. If test lamp lights and stays
ON, go to Test Lamp Stays ON procedure.
TEST LAMP STAYS ON
There is either a short circuit or a fault in an elec-
tronic module. Two fuses in the Power Distribution
Center (PDC) feed the modules with ignition off
draw.
²Interior lamps fuse (10 Amp) (IOD) PDC.
²Fuel pump fuse (20 Amp) in PDC
(1) Remove interior lamp and fuel pump fuses. By
removing these fuses all ignition off draw from the
vehicle electronics will be disconnected. The test
lamp should go out. If test lamp goes out go to Step
2. If test lamp does not go out there is a current
draw or short circuit. Refer to Group 8W, Wiring Dia-
grams.
(2) Install the fuel pump fuse. If test lamp lights,
there is a current draw or short circuit in the A14
wiring circuit feed.
(a) Disconnect Powertrain Control Module.
(b) If test lamp goes out, replace Powertrain
Control Module.
(c) If test lamp does not go out, there is a cur-
rent draw or short circuit in the A14 circuit feed.
Refer to Group 8W, Wiring Diagrams.
(3) Install the interior lamp fuse. If test lamp
lights, there is a current draw or short circuit in the
M01 circuit. Refer to Group 8W, Wiring Diagrams. If
test lamp stays out, go to Step 4
(4) Use a multi-meter that has at least a range of
200 milliamperes. Install meter between the battery
negative cable and battery negative post (Fig. 6).
Carefully remove the test lamp without disconnecting
the meter. After all modules time-out the total vehi-
cle IOD should be less than 10 milliamperes. If igni-
tion off draw is more than 10 milliamperes go to Step
5.
(5) Remove both fuses from the Power Distribution
Center:
PLBATTERY 8A - 3
DIAGNOSIS AND TESTING (Continued)

²Fuel pump fuse (20 Amp)
²Interior lamps fuse (10 Amp)
(6) If there is any reading with fuses removed
there is a current draw or short circuit in the wiring.
Refer to Group 8W, Wiring Diagrams. If OK go to
Step 7.
(7) Install interior lamp fuse. After installing fuse,
the current can reach 250 milliamperes. After time-out the reading should not exceed 8 milliamperes. If
NOT OK go to Step 8. If OK go to Step 9.
²Ignition key lamp system
²Radio
²Remote keyless entry module, if equipped
(8) Disconnect radio and ignition switch key lamp
one component at time, to see if any component is at
fault. If the high reading is not eliminated there is a
short circuit in the wiring. Refer to Group 8W, Wir-
ing Diagrams.
CAUTION: Always disconnect the meter before
opening a door.
(9) Remove interior lamps fuse and install the fuel
pump fuse. The reading should be between 1-3 milli-
amperes. If reading is higher than 3 milliamperes:
(a) Disconnect Powertrain Control Module.
(b) If reading drops to zero, replace Powertrain
Control Module.
(c) If reading remains the same there is a cur-
rent draw or short circuit in the A14 circuit. Refer
to Group 8W, Wiring Diagrams.
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.(1) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(2) Battery OK.(1) Replace Battery
(2) Check state of charge. Refer to
Test Indicator.
TEST INDICATOR
Check Charge Eye Color(1) GREEN
(2) BLACK
(3) CLEAR(1) Battery is charged. Perform
Battery 0pen Circuit Voltage Test
(2) Perform Battery Charging
procedure.
(3) Replace Battery.
BATTERY OPEN CIRCUIT
VOLTAGE TEST(1) Battery is above 12.40 Volts
(2) Battery is below 12.40 Volts.(1) Perform the Battery Load Test.
(2) Perform Battery Charging
procedure.
BATTERY CHARGING (1) Battery accepted Charge.
(2) Battery will not accept charge(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test
(2) Perform Charging a Completely
Discharged Battery.
BATTERY LOAD TEST (1) Acceptable minimum voltage.
(2) Unacceptable minimum voltage(1) Battery is OK to put in use,
perform Battery Ignition Off Draw
Test.
(2) Replace Battery and perform
Battery Ignition Off Draw Test.
CHARGING A COMPLETELY
DISCHARGED BATTERY(1) Battery accepted charge.
(2) Battery will not accept charge.(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test.
(2) Replace Battery.
IGNITION OFF DRAW TEST (1) IOD is 5-25 Milliamperes.
(2) IOD Exceeds 25 Milliamperes.(1) Vehicle is normal.
(2) Eliminate excess IOD draw.
Fig. 4 Disconnect Battery Negative Cable
8A - 4 BATTERYPL
DIAGNOSIS AND TESTING (Continued)

BATTERY LOAD TEST
A fully charged battery must have cranking capac-
ity, to provide the starter motor and ignition system
enough power to start the engine over a broad range
of ambient temperatures. A battery load test will ver-
ify the actual cranking capability of the battery.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELYLOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY
RESULT.
(1) Remove both battery cables, negative cable
first. The battery top, cables and posts should be
clean. If green dot is not visible in indicator, charge
the battery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 7). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 8).
(3) Allow the battery to stabilize for 2 minutes,
and then verify open circuit voltage.
(4) Rotate the load control knob on the tester to
maintain 50% of the battery cold crank rating for 15
seconds (Fig. 9). Record the loaded voltage reading
and return the load control to off. Refer to the Bat-
tery Specifications at the rear of this Group.
(5) Voltage drop will vary according to battery
temperature at the time of the load test. Battery
temperature can be estimated by the temperature of
Fig. 5 Ignition OFF (IOD) Test
Fig. 6 Milliampere Meter Connection
Fig. 7 Volt-Ammeter Load Tester Connections
Fig. 8 Remove Surface Charge From Battery
PLBATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued)

(3) Rinse soda solution from battery with clear
water and blot battery dry with paper toweling. Dis-
pose of toweling in a safe manner. Refer to the
WARNINGS on top of battery.
(4) Inspect battery case and cover for cracks, leak-
age or damaged hold down ledge. If battery is dam-
aged replace it.
(5) Inspect battery tray for damage caused by acid
from battery. If acid is present, clean area with bak-
ing soda solution.
(6) Clean battery posts with a battery post clean-
ing tool (Fig. 13).
(7) Clean battery cable clamps with a battery ter-
minal cleaning tool (Fig. 14). Replace cables that are
frayed or have broken clamps.
REMOVAL AND INSTALLATION
BATTERY
REMOVAL
(1) Make sure ignition switch is in OFF position
and all accessories are OFF.
(2) Remove battery negative cable then the posi-
tive cable (Fig. 4).
(3) Remove battery thermoguard cover (Fig. 15).
WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.(4) Remove battery hold down clamp (Fig. 16) and
battery from vehicle.
INSTALLATION
(1) Install battery in vehicle making sure that it is
properly positioned on battery tray.
Fig. 12 Cleaning BatteryFig. 13 Cleaning Battery Post
Fig. 14 Cleaning Battery Cable Terminal
8A - 8 BATTERYPL
SERVICE PROCEDURES (Continued)

(2) Install battery hold down clamp, making sure
that it is properly positioned on battery.
(3) Place thermoguard cover over the battery and
snap it together with battery tray (Fig. 17). The bat-
tery tray pencil strut may have to be loosened on one
end to install the thermoguard cover. After the ther-
moguard cover is in place, tighten pencil strut as
necessary.(4) Connect battery cable clamps to battery posts
and making sure top of clamp is flush or below with
top of post (Fig. 18). Install battery positive cable
first.
(5) Tighten clamp nuts securely.
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to Battery Removal.
(2) Remove battery tray pencil strut. Remove bat-
tery tray, refer to (Fig. 17).
INSTALLATION
For installation reverse above procedures.
FRESH AIR INLET TUBE REMOVAL
REMOVAL
(1) Ensure that the ignition switch and all acces-
sories are OFF
(2) Remove battery negative cable first then the
positive cable (Fig. 4).
(3) Remove battery thermoguard cover (Fig. 15).
Fig. 15 Battery Thermoguard
Fig. 16 Battery Hold-Down
Fig. 17 Battery Tray Removal
Fig. 18 Remove and Install Battery Cables
PLBATTERY 8A - 9
REMOVAL AND INSTALLATION (Continued)

STARTING
CONTENTS
page page
GENERAL INFORMATION
BOSCH STARTER........................ 1
INTRODUCTION......................... 1
SUPPLY CIRCUIT AND CONTROL CIRCUIT.... 1
DIAGNOSIS AND TESTING
FEED CIRCUIT RESISTANCE TEST........... 2
FEED CIRCUIT TEST...................... 2
STARTER CONTROL CIRCUIT.............. 1STARTING SYSTEM TEST................. 4
REMOVAL AND INSTALLATION
SAFETY SWITCHES...................... 6
STARTER RELAY........................ 7
STARTER .............................. 6
SPECIFICATIONS
STARTER .............................. 7
TORQUE............................... 7
GENERAL INFORMATION
INTRODUCTION
The starting system (Fig. 1) has:
²Ignition switch
²Starter relay
²Neutral starting and back up switch
²Clutch pedal position switch
²Wiring harness
²Battery
²Starter motor with an integral solenoid
BOSCH STARTER
The Bosch is a permanent magnet starter motor. A
planetary gear train transmits power between starter
motor and pinion shaft. The fields have six perma-
nent magnets. The starter system consists of two
separate circuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate cir-
cuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
DIAGNOSIS AND TESTING
STARTER CONTROL CIRCUIT
The starter control circuit has:
²Starter solenoid
²Starter relay²Neutral starting and back up switch with auto-
matic transmissions
²Clutch pedal position switch with manual trans-
mission
²Ignition switch
²Battery
²All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 1 Starting System
PLSTARTING 8B - 1

To disable the ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for proper relay location.
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled
to prevent engine start while performing the follow-
ing tests.
(1) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 2). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp (Fig. 2). Rotate and hold
the ignition switch key in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between the cable clamp and
post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point (Fig.
3). Rotate and hold the ignition switch in the
START position. If voltage reads above 0.2 volt,
correct poor contact at ground cable attaching
point. If voltage reading is still above 0.2 volt after
correcting poor contacts, replace ground cable.
(3) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 4). Hold the ignition switch
key in the START position. If voltage reads above 0.2
volt, correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid (Fig. 5).
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at battery cable to solenoid connec-
tion. If reading is still above 0.2 volt after correct-
ing poor contacts, replace battery positive cable.(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
FEED CIRCUIT TEST
The following procedure will require a suitable
volt-ampere tester (Fig. 6).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 2 Test Battery Connection Resistance
Fig. 3 Test Ground Circuit Resistance
8B - 2 STARTINGPL
DIAGNOSIS AND TESTING (Continued)

(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 7). Refer to the operating instructions
provided with the tester being used.
(2) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location. The 2.5L Diesel Engine, to disable the
engine from starting, disconnect wire connector from
the Fuel Solenoid.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARKposition or with the clutch pedal depressed and SET
parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
6).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps or the Diesel engine
above 450 amps, check for engine seizing or faulty
starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps or Diesel engine above 500 amps,
the problem is the starter. Replace the starter refer
to starter removal.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
Fig. 6 Volt Ampere Tester
Fig. 7 Volt-Ampere Tester Connections
Fig. 4 Test Starter Motor Ground
Fig. 5 Test Battery Positive Cable Resistance
PLSTARTING 8B - 3
DIAGNOSIS AND TESTING (Continued)

charge battery if necessary. Disconnect all testing
equipment and connect ASD relay or the Fuel Sole-
noid. Start the vehicle several times to assure the
problem has been corrected.
STARTING SYSTEM TEST
For circuit descriptions and diagrams, refer to
8W-21, Starting System in Group 8W, Wiring Dia-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Group 8A, Battery
for more information.²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Clutch Pedal Position Switch- Visually
inspect the clutch pedal position switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Park/Neutral Position Switch- Visually
inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
²Starter- Visually inspect the starter for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
8B - 4 STARTINGPL
DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
ENGAGE.1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position switch
(auto trans) faulty or mis-adjusted.
6. Clutch pedal position switch
(man trans) faulty.
7. Starter solenoid faulty.
8. Starter assembly faulty.1. Refer to Group 8A, Battery. Charge or replace
battery, if required.
2. Refer to Feed Circuit Resistance Test and
Feed Circuit Test in this section.
3. Refer to Relay Test, in this section. Replace
relay, if necessary.
4. Refer to Ignition Switch Test, in Group 8D
Ignition System or Group 8W, Wiring Diagrams.
Replace switch, if necessary.
5. Refer Park/Neutral Position Switch Test, in
Group 21, Transaxle. Replace switch, if
necessary.
6. Refer to Clutch Pedal Position Switch Test, in
Group 6, Clutch. Replace switch, if necessary.
7. Refer to Solenoid Test, in this section.
Replace starter assembly, if necessary.
8. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter assembly faulty.
4. Engine seized.1. Refer to Group 8A, Battery. Charge or replace
battery as necessary.
2. Refer to the Feed Circuit Resistance Test and
the Feed Circuit Test in this section. Repair as
necessary.
3. If all other starting system components and
circuits check OK, replace starter assembly.
4. Refer to Group 9 Engine, for diagnostic and
service procedures.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.1. Broken teeth on starter ring gear.
2. Starter assembly faulty.1. Remove starter. Inspect ring gear and replace
if necessary.
2. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER DOES NOT
DISENGAGE.1. Starter improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter assembly faulty.1. Install starter. Tighten starter mounting
hardware to correct torque specifications.
2. Refer to Relay Test, in this section. Replace
relay, if necessary.
3. Refer to Ignition Switch Test, in Group 8D,
Ignition System. Replace switch, if necessary.
4. If all other starting system components and
circuits check OK, replace starter assembly.
PLSTARTING 8B - 5
DIAGNOSIS AND TESTING (Continued)