DODGE NEON 1999 Service Repair Manual

HEADLAMP DIAGNOSIS
Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Refer to Group 8W,
Wiring Diagrams.
Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on
a given vehicle.
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of-charge,
refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS
BURN OUT1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING1. Charging system output too low. 1. Test and repair charging system, refer to
Group 8A.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.5. Repair connector terminal or wire splice.
1. Headlamps stay on with
key out (DRLM equipped
vehicles).1. Failed DRLM 1. Replace DRLM.
*Canada vehicles must have lamps ON.
8L - 2 LAMPSPL
DIAGNOSIS AND TESTING (Continued)

FOG LAMP
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM WITH
ENGINE IDLING OR IGNITION
TURNED OFF.1. Loose or corroded battery cables. 1. Clean and secure battery cable
clamps and posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS ARE DIM WITH
ENGINE RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system.
Refer to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
2. High resistance in fog lamp
circuit.2. Test amperage draw of fog lamp
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.4. Repair connector terminal or wire
splice.
5. Defective or burned out bulb. 5. Replace bulb.
PLLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 4
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 4ADJUSTMENTS
FOG LAMP ALIGNMENT................... 4
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN.............................. 4
GENERAL INFORMATION
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method
provided in this section.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 1).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen from 178 mm (7 in.) below the headlamp cen-
ter line. The side- to-side left edge of low beam hot
spot should be 127 mm (5 in.) to the right of head-
lamp center line (Fig. 1). The high beams on a vehi-
cle with aero headlamps cannot be aligned. The high
beam pattern should be correct when the low beams
are aligned properly.
To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern.
FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to Alignment
Screen Preparation paragraph in this section. Disen-
gage the wire connectors from the back of the head-
lamp bulbs to disable the headlamps. This will allow
a more accurate projection reading of the fog lamps.
Turn on the headlamp switch and actuate the fog
lamp switch. A properly aligned fog lamp will project
a pattern on the alignment screen 100 mm (4 in.)
below the fog lamp centerline and straight ahead
(Fig. 2).
8L - 4 LAMPSPL

Fig. 1 Headlamp Alignment Screen ± Typical
Fig. 2 Lamp Alignment Screen
PLLAMPS 8L - 5
ADJUSTMENTS (Continued)

LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP BULB . . . 7
DOME LAMP BULB....................... 8
FOG LAMP BULB......................... 6
FRONT SIDE MARKER LAMP BULB.......... 7
HEADLAMP BULB........................ 6
LICENSE PLATE LAMP BULB............... 8PARK AND TURN SIGNAL LAMP BULB........ 6
REAR CARGO LAMP BULB................. 8
TAIL, STOP, BACK-UP AND TURN SIGNAL
LAMP BULB........................... 7
UNDERHOOD LAMP BULB................. 8
VISOR VANITY LAMP BULB................. 8
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Disengage wire connector from headlamp bulb
connector.
(3) Remove retaining ring holding bulb to back of
headlamp module.
(4) Pull bulb from back of headlamp module (Fig.
1).
INSTALLATION
CAUTION: Do not touch the glass of halogen
bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
Reverse the preceding operation.
FOG LAMP BULB
REMOVAL
(1) Remove fog lamp from behind fascia.(2) Disengage wire connector from fog lamp bulb
base.
(3) Remove bulb from lamp (Fig. 2).
INSTALLATION
CAUTION: Do not touch the glass of halogen
bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
Reverse the preceding operation.
PARK AND TURN SIGNAL LAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Remove screws holding park and turn signal
lamp to headlamp module.
(3) Separate lamp from module.
(4) Remove bulb socket from back of lamp.
(5) Pull bulb from socket (Fig. 3).
INSTALLATION
Reverse the preceding operation.
Fig. 1 Headlamp Bulb
Fig. 2 Fog Lamp Bulb
8L - 6 LAMPSPL

FRONT SIDE MARKER LAMP BULB
REMOVAL
(1) Reach behind front bumper fascia forward of
front wheel.
(2) Remove socket from side marker lamp.
(3) Pull bulb from socket (Fig. 4).
INSTALLATION
Reverse the preceding operation.
CENTER HIGH MOUNTED STOP LAMP BULB
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Remove bulb socket from center high mounted
stop lamp (Fig. 5).
(3) Pull bulb from socket.
INSTALLATION
Reverse the preceding operation.
TAIL, STOP, BACK-UP AND TURN SIGNAL LAMP
BULB
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Separate trunk lining from rear closure panel
to gain access to back of tail lamp.
(3) Rotate and remove bulb socket from tail lamp
through openings in rear closure panel (Fig. 6).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Rotate and install bulb socket into tail lamp
through openings in rear closure panel.
(3) Install trunk lining to rear closure panel.
(4) Close and secure trunk lid.
Fig. 3 Park and Turn Signal Lamp Bulb
Fig. 4 Front Side Marker
Fig. 5 CHMSL Bulb
Fig. 6 Tail and Stop Lamp Bulb
PLLAMPS 8L - 7
REMOVAL AND INSTALLATION (Continued)

LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove screws holding license plate lamp to
rear bumper (Fig. 7).
(2) Separate lamp from bumper.
(3) Remove bulb socket from lamp.
(4) Pull bulb from socket.
INSTALLATION
Reverse the preceding operation.
UNDERHOOD LAMP BULB
REMOVAL
(1) Disconnect the wire harness connector from the
underhood lamp.
(2) Rotate the bulb counter-clockwise. Remove it
from the lamp socket.
INSTALLATION
(1) Insert the replacement bulb in the lamp base
socket and rotate it clockwise.
(2) Connect the wire harness connector.
DOME LAMP BULB
REMOVAL
(1) Insert a trim stick between the headliner and
dome lamp lens.
(2) Carefully pry downward on the four corners of
the lamp lens.
(3) Separate lamp lens from lamp.
(4) Grasp bulb and pull from lamp socket.
INSTALLATION
(1) Position bulb in socket and snap into place.
(2) Position lens on lamp and snap into place.
VISOR VANITY LAMP BULB
REMOVAL
(1) Lower visor.
(2) Insert a small flat bladed tool between the
lamp lens and lamp.
(3) Carefully pry lens outward.
(4) Remove bulb from socket.
INSTALLATION
(1) Position bulb in socket and snap into place.
(2) Position lens on lamp and snap into place.
REAR CARGO LAMP BULB
The trunk lamp snaps into the rear shelf panel
reinforcement under/below the package shelf.
REMOVAL
(1) Insert a trim stick or small flat blade between
the lamp lens and rear shelf reinforcement panel.
(2) Pry the lamp lens downward.
(3) Pull bulb from socket
INSTALLATION
(1) Push bulb into socket.
(2) Position the lamp in the rear shelf reinforce-
ment panel and snap into place.
Fig. 7 License Plate Lamp
8L - 8 LAMPSPL
REMOVAL AND INSTALLATION (Continued)

LAMP SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)............................. 10
DOME LAMP........................... 11
FOG LAMP.............................. 9
FRONT SIDE MARKER LAMP.............. 10
HEADLAMP MODULE..................... 9LICENSE PLATE LAMP................... 11
PARK AND TURN SIGNAL LAMP............. 9
REAR CARGO LAMP..................... 11
TAIL, STOP AND TURN SIGNAL LAMP........ 10
UNDERHOOD LAMP..................... 11
VISOR VANITY LAMP..................... 11
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
(1) Release hood latch and open hood.
(2) From behind bumper fascia, remove bolt hold-
ing outboard end of module to fender and closure
panel.
(3) Loosen bolts holding inboard end of module to
radiator closure panel and remove bolt to grille.
(4) Remove bolts attaching top of module to upper
crossmember (Fig. 1).
(5) Disconnect wire connector from headlamp and
parking lamp sockets.
(6) Remove headlamp module from vehicle.
INSTALLATION
For installation, reverse the above procedures.
FOG LAMP
REMOVAL
(1) Remove bolt holding fog lamp to radiator clo-
sure panel (Fig. 2).
(2) Separate fog lamp from radiator closure panel.
(3) Pull fog lamp through opening in fascia.
(4) Disengage wire connector from fog lamp bulb
base.
(5) Separate fog lamp from vehicle.
INSTALLATION
Reverse the preceding operation.
PARK AND TURN SIGNAL LAMP
REMOVAL
(1) Release hood latch and open hood.
(2) Remove screws holding lamp to headlamp mod-
ule (Fig. 3).
(3) Separate park and turn signal lamp from vehi-
cle.
(4) Disengage wire connector from back of lamp
socket.
Fig. 1 Headlamp Module
Fig. 2 Fog Lamp
PLLAMPS 8L - 9

INSTALLATION
Reverse the preceding operation.
FRONT SIDE MARKER LAMP
REMOVAL
(1) Remove socket and bulb from side marker
lamp.
(2) Remove nuts holding side marker lamp to front
bumper fascia (Fig. 4).
(3) Separate side marker lamp from vehicle.
INSTALLATION
Reverse the preceding operation.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Remove socket and bulb from lamp.
(3) Remove nuts holding center high mounted stop
lamp to trunk lid (Fig. 5).
(4) Pull CHMSL from trunk lid.(5) Separate CHMSL bezel from trunk lid.
INSTALLATION
Reverse the preceding operation.
TAIL, STOP AND TURN SIGNAL LAMP
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Remove trunk trim panel from tail lamp area,
if equipped.
(3) Remove sockets and bulbs from lamp.
(4) Remove nuts holding tail lamp to rear closure
panel (Fig. 6).
(5) Separate tail lamp from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 3 Park and Turn Signal Lamp
Fig. 4 Front Side Marker Lamp
Fig. 5 Center High Mounted Stop Lamp
Fig. 6 Tail, Stop and Turn Signal Lamp
8L - 10 LAMPSPL
REMOVAL AND INSTALLATION (Continued)

LICENSE PLATE LAMP
REMOVAL
(1) Remove screws holding license plate lamp to
rear bumper fascia (Fig. 7).
(2) Separate license plate lamp from bumper.
(3) Remove socket and bulb from lamp.
INSTALLATION
Reverse the preceding operation.
UNDERHOOD LAMP
REMOVAL
(1) Open and support hood.
(2) Remove lamp bulb.
(3) Disengage lamp wire connector.
(4) Remove the screw attaching lamp to hood.(5) Separate lamp from vehicle.
INSTALLATION
(1) Position lamp on hood and install screw.
(2) Route lamp wire through hood silencer pad and
connect lamp wire connector.
(3) Install lamp bulb.
(4) Remove hood support and close hood.
DOME LAMP
REMOVAL
(1) Insert a trim stick between the headliner and
dome lamp lens.
(2) Carefully pry downward on the four corners of
the lamp lens.
(3) Separate lamp lens from lamp.
(4) Disengage wire connector and remove from
vehicle.
INSTALLATION
Reverse the removal procedure.
VISOR VANITY LAMP
The visor vanity lamp is incorporated in the visor
assembly. Replace the visor if the lamp has failed.
REAR CARGO LAMP
REMOVAL
(1) Insert a trim stick or small flat blade between
the lamp lens and rear shelf reinforcement panel.
(2) Pry the lamp lens downward.
(3) Disengage wire connectors.
(4) Separate lamp from vehicle.
INSTALLATION
Reverse the removal procedure.
Fig. 7 License Plate Lamp
PLLAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)