light DODGE NEON 1999 Service Manual PDF

LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CITYLIGHT LAMP BULB.................... 3
FOG LAMP BULB......................... 3FRONT TURN SIGNAL LAMP BULB........... 2
HEADLAMP BULB........................ 2
SIDE REPEATER LAMP BULB............... 4
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Disengage wire connector to headlamp bulb.
(3) Remove headlamp assembly from vehicle.
(4) Remove rubber seal boot (Fig. 1).
(5) Disengage retaining ring from headlamp (Fig.
2).
(6) Pull headlamp bulb from back of headlamp
assembly (Fig. 3).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers of other possibly oily surface. Reduced
bulb life will result.
(1) Insert headlamp bulb to headlamp assembly.
(2) Install retaining ring to headlamp assembly.
(3) Install rubber seal boot.
(4) Engage wire connector to headlamp bulb base.
(5) Install headlamp assembly into vehicle.
(6) Verify headlamp alignment.
FRONT TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove screws holding the park and turn sig-
nal lamp to the headlamp assembly.
(2) Separate the turn signal lamp from the head-
lamp module.
(3) Rotate front turn signal lamp socket one quar-
ter turn counter-clockwise.
(4) Pull socket from back of lamp.
Fig. 1 Rubber Boot Seal
Fig. 2 Headlamp Bulb Retaining Ring
Fig. 3 Headlamp Bulb
8L - 2 LAMPSPL

(5) Pull bulb from socket (Fig. 4).
INSTALLATION
(1) Push bulb into socket.
(2) Insert socket into back of turn signal lamp.
(3) Rotate front turn signal socket clockwise one
quarter turn.
(4) Install front turn signal lamp onto vehicle.
(5) Verify lamp operation.
CITYLIGHT LAMP BULB
REMOVAL
(1) Pull citylight lamp socket from rubber bushing
in headlamp housing (Fig. 5).
(2) Rotate counterclockwise and pull bulb from
socket (Fig. 6).
INSTALLATION
(1) Position citylight lamp bulb to lamp socket.
(2) Push and twist bulb into socket.
(3) Push citylight lamp into bushing in headlamp
housing.
FOG LAMP BULB
REMOVAL
(1) Remove fog lamp assembly from fascia.
(2) Disengage fog lamp housing from bracket
assembly.
(3) Compress Wire Bulb Retainer (Fig. 7) on fog
lamp housing and pull away from lock tabs.
NOTE: Do not pull bulb from base.
(4) Disconnect Bulb Power and Ground Leads from
harness and bulb base. (Fig. 8).
INSTALLATION
CAUTION: Do not touch the glass of halogen
bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
(1) Align locator tabs and insert new bulb into fog
lamp housing.
(2) Connect Bulb Ground Lead to bulb base.
Fig. 4 Front Turn Signal Lamp Bulb
Fig. 5 Citylight Lamp Socket
Fig. 6 Citylight Lamp Bulb
Fig. 7 Wire Bulb Retainer
PLLAMPS 8L - 3
REMOVAL AND INSTALLATION (Continued)

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 8
SPECIFICATIONS
EXTERIOR LAMPS........................ 8INTERIOR LAMPS........................ 8
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Back-up...............................P21W
Center High Mounted Stop..................921
Front Fog Lamp..........................H-3
Headlamp...............................H-4
License Plate...........................W5W
Front Turn Signal.....................P21/5W
Tail/Stop.............................P21/5W
Rear Turn Signal.......................P21W
Rear Fog Lamp.........................P21W
Citylight...............................T4W
Side Repeater...........................T4W
INTERIOR LAMPS
LAMP BULB
ABS.................................PC194
Airbag...............................PC194
AshTray................................161
Brake Warning System Indicator...........PC194
Cigar Lighter............................203
Climate Controls.........................203
Console Gear Selector......................161
Dome Light..............................578
Glove Box...............................194
High Beam Indicator....................PC194
Ignition Key.............................161
Instrument Cluster.....................PC194
Rear Cargo..............................912
Seat Belt Indicator.......................PC74
Service Engine Soon....................PC194
Turn Signal Indicator....................PC194
Underhood..............................105
Visor Vanity.........................6501966
Volts Indicator..........................PC74
8L - 8 LAMPSPL

DIAGNOSIS AND TESTING
AIRBAG SYSTEM TEST
(1) Disconnect and isolate the negative battery
cable.
(2) Connect scan tool (DRB) to Data Link connec-
tor, located at right side of the steering column and
at the lower edge of the lower instrument panel.
(3) Turn the ignition key to ON position. Exit vehi-
cle with scan tool. Use the latest version of the
proper cartridge.
(4) After checking that no one is inside the vehicle,
connect the battery negative terminal.
(5) Using the scan tool, read and record active
diagnostic code data.
(6) Read and record any stored diagnostic codes.
(7) Refer to the Passive Restraint Diagnostic Test
Manual if any diagnostic codes are found in Step 5 or
Step 6.
(8) Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnos-
tic codes will not erase. Refer to the Passive
Restraint Diagnostic Test Manual to diagnose the
problem.If the airbag warning lamp either fails
to light with the ignition switch on, or the light
goes on and stays on, there is a system malfunc-
tion. Refer to the Passive Restraint Diagnostic
Test Manual to diagnose the problem.
SERVICE PROCEDURES
CLEANUP PROCEDURE
Roll or fold the passenger airbag towards the
instrument panel surface and close the door over the
folded bag. Then tape the door shut.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
4). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
vacuum cleaning may to necessary to decontaminate
the interior of the vehicle.
NOTE: Dispose deployed airbag properly, contact
dealer or government agency for disposal recom-
mendations.
SERVICE OF DEPLOYED AIRBAG MODULE
DRIVER AIRBAG
After a Driver Airbag Module has been deployed
the following components must be replaced becausethey cannot be reused. Other driver airbag system
components are replaced if damaged.
²Driver Airbag Module
²Clockspring assembly
PASSENGER AIRBAG
After a Passenger Airbag Module has been
deployed the following components must be replaced
because they cannot be reused.
²Passenger Airbag Module
²Right trim panel
The lower instrument panel knee blocker, top
cover, and any other components should be replaced
if damaged.
HANDLING AIRBAG MODULE
DEPLOYED MODULE
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED
The airbag module(s) must be stored in its original
special container until used for service. At no time
should a source of electricity be permitted near the
inflator on the back of an airbag module. When car-
rying or handling an undeployed airbag module, the
trim side of the airbag should be pointing away from
the body to minimize possibility of injury if acciden-
Fig. 4 Vacuum Heater and A/C Outlets
PLRESTRAINT SYSTEM 8M - 3

tal deployment occurs. Do not place undeployed air-
bag face down on a solid surface, the airbag will
propel into the air if accidental deployment occurs.
MAINTENANCE INSPECTION
(1) Check the airbag warning lamp for proper
operation as follows:
(a) Turn ignition switch to the ON position, the
airbag warning lamp should light. If not, test the
system using a scan tool and Passive Restraint
System Diagnostic Procedures Manual. Repair as
required.
(b) The airbag warning lamp lights, but fails to
go out after eight seconds. Test the system using a
scan tool and Passive Restraint System Diagnostic
Procedures Manual. Repair as required.
(c) After correcting active malfunction erase
stored diagnostic codes.
REMOVAL AND INSTALLATION
AIRBAG CONTROL MODULE (ACM)
REMOVAL
WARNING: THE ACM CONTAINS A SAFING SEN-
SOR WHICH ENABLES THE SYSTEM TO DEPLOY
THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOY-
MENT, NEVER CONNECT THE ACM ELECTRICALLY
TO THE SYSTEM WHILE VEHICLE BATTERY IS
CONNECTED.
DISCONNECT AND ISOLATE THE BATTERY NEG-
ATIVE (GROUND) CABLE BEFORE BEGINNING ANY
AIRBAG SYSTEM COMPONENT REMOVAL OR
INSTALLATION PROCEDURE. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT
BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG
COMPONENTS.
CAUTION: Failure to follow the parking brake ser-
vice procedures can result in damage to the park-
ing brake mechanism.
(1) Disconnect and isolate the battery negative
cable.
(2) Manual transaxle only, remove shifter knob
fastener and remove shifter knob.
(3) Remove screws attaching rear of center console
assembly to console bracket (Fig. 5) or (Fig. 6).
(4) Remove the two screws located in cup holders
(Fig. 7), attaching front of center console assembly to
console bracket.
Fig. 5 Attaching Screws At Rear Of Center Console
With/Without Arm Rest
Fig. 6 Attaching Screws At Rear Of Center Console
With Arm Rest
Fig. 7 Attaching Screws At Front Of Center Console
8M - 4 RESTRAINT SYSTEMPL
SERVICE PROCEDURES (Continued)

(5) Raise park brake hand lever assembly as high
as it will go for required clearance to remove center
console.
(6) Remove center console assembly from vehicle.
WARNING: THE AUTO ADJUSTING FEATURE OF
THIS PARKING BRAKE LEVER ASSEMBLY CON-
TAINS A CLOCK SPRING LOADED TO APPROXI-
MATELY 20 POUNDS. DO NOT RELEASE THE AUTO
ADJUSTER LOCKOUT DEVICE BEFORE INSTALL-
ING CABLES INTO THE EQUALIZER. KEEP HANDS
OUT OF AUTO ADJUSTER SECTOR AND PAWL
AREA. FAILURE TO OBSERVE CAUTION IN HAN-
DLING THIS MECHANISM COULD LEAD TO SERI-
OUS INJURY.
WHEN REPAIRS TO THE PARK BRAKE HAND
LEVER ASSEMBLY OR CABLES IS REQUIRED, THE
AUTO ADJUSTER MUST BE RELOADED AND
LOCKED OUT.
(7) Lower park brake lever handle.
(8) Grasp park brake lever output cable by hand
and pull upward. Continue pulling on cable until a
3/16 in. drill bit can be inserted into handle and sec-
tor gear of park brake mechanism (Fig. 8). This will
lock the park brake mechanism and take tension off
park brake cables.
(9) Remove both rear park brake cables from the
park brake cable equalizer (Fig. 9).
(10) Remove wiring harness electrical connector
for brake warning light from park brake lever (Fig.
10).
(11) Remove the two nuts (Fig. 11) attaching park
brake lever to console bracket. Remove park brake
lever mechanism from vehicle.
(12) Remove module mounting nuts and remove
module (Fig. 12).
(13) Disconnect ACM 23-PIN connector (Fig. 13).
(14) Remove Airbag Control Module.
Fig. 8 Locking Pin Installed In Park Brake
Mechanism
Fig. 9 Removing Park Brake Cables From Equalizer
Fig. 10 Brake Warning Lamp Connection To Park
Brake Lever
Fig. 11 Park Brake Lever Attachment To Console
Bracket
PLRESTRAINT SYSTEM 8M - 5
REMOVAL AND INSTALLATION (Continued)

ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1
REAR WINDOW DEFOGGER SWITCH........ 1
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM..................... 1GRID LINES............................ 2
REAR WINDOW DEFOGGER SWITCH........ 2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR......... 3
DESCRIPTION AND OPERATION
INTRODUCTION
For proper operation of the Rear Window Defogger
system refer to the Owner's Manual.
The system consists of a rear glass with two verti-
cal bus bars and a series of electrically connected
grid lines fired on the inside surface. A control switch
and a timer relay combined into a single assembly is
used on all models (Fig. 1).
Circuit protection is provided by a maxi fuse,
located in the Power Distribution Center, for the
heated grid circuit and by a fuse for the relay control
circuit.
When the switch is turned to the ON position, cur-
rent is directed to the rear defogger grid lines. The
heated grid lines heat the rear glass to clear the sur-
face of fog or frost.
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments, care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch is a control
switch and timer relay integrated into a single panel
mounted assembly. Actuating the switch energizes
the circuit which allows current to flow through the
grid lines. Upon initial actuation for approximately
eight to ten minutes, or until either the switch or
ignition is turned off. An indicating lamp illuminates
a lens inlaid in the control switch.
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM
Electrically heated rear window defogger operation
can be checked in vehicle in the following manner:
(1) Turn ignition switch to the ON position.
(2) Connect an ammeter in series with the battery.
Push the defogger control switch to the ON position.
A distinct increase in amperage draw should be
noted.
(3) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected in three to four minutes
of operation.
(4) Using a DC voltmeter, connect negative lead to
Point B, and the positive lead to Point A (Fig. 2). The
voltmeter should read 10-14 volts.
(5) Step 2, Step 3 or Step 4 above will confirm
system operation. Indicator light illumination means
that there is power available at the output of the
relay only, and does not necessarily verify system
operation.
Fig. 1 Rear Window Defogger
PLELECTRICALLY HEATED SYSTEMS 8N - 1

(6) If turning the switch ON produced no distinct
current draw on the ammeter the problem should be
isolated in the following manner:
(a) Confirm the ignition switch is ON.
(b) Ensure that the heated rear glass feed wire
is connected to the terminal or pigtail and that the
ground wire is in fact grounded.
(c) Ensure that the maxi-fuse and control circuit
fuse are OK and all electrical connections are
secure.
(7) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing is defective:
(a) Control switch/timer relay module.
(b) All rear window grid lines would have to be
broken or one of the feed wires are not connected
for the system to be inoperative.
(8) If turning the switch ON produces severe volt-
meter deflection, the circuit should be closely checked
for a shorting condition.
(9) If the system operation has been verified but
indicator lamp does not light, replace the switch.
(10) For detailed wiring information, refer to group
8W, Wiring Diagrams.
GRID LINES
The horizontal grid lines and vertical bus bar lines
printed and fired on inside surface of rear window
glass (Fig. 2) comprise an electrical parallel circuit.
The electrically conductive lines are composed of a
silver-ceramic material which when fired on glass
becomes bonded to the glass and is highly resistant
to abrasion. It is possible, however, that a break may
occur in an individual grid line resulting in no cur-
rent flow through the line. To detect breaks in grid
lines the following procedure is required:
(1) Turn ignition ON and turn control switch to
ON. The indicator light should come on.(2) Using a DC voltmeter with 0-15 volt range,
contact terminal B with negative lead of voltmeter.
With positive lead of voltmeter, contact terminal A
(Fig. 2). The voltmeter should read 10-14 volts. A
lower voltage reading indicates a poor connection in
the feed or the ground circuit.
(3) With negative lead of voltmeter, contact a good
body ground point. The voltage reading should not
change.
(4) Connect negative lead of voltmeter to terminal
B and touch each grid line at Mid-Point with Positive
lead. A reading of:
²Approximately 6 volts indicates the line is OK
²0 volts indicates a break in line between Mid-
Point C and terminal A
²10-14 volts indicates a break between Mid-Point
C and terminal B
Move the lead toward the break and voltage will
change as soon as break is crossed. Refer to (Fig. 2)
and (Fig. 3).
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch may be tested in-
vehicle or bench tested. In vehicle testing is accom-
plished in the following manner:
(1) Remove the switch from the instrument panel
but leave the switch connected, refer to Group 8E,
Fig. 2 Rear Glass Grid Line Test
Fig. 3 Systems Electrical Circuit
8N - 2 ELECTRICALLY HEATED SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

Instrument Panel and Systems for removal proce-
dures.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, check for battery voltage at
Pin 3 and Pin 4 (Fig. 3), (Fig. 4).
(a) If OK, go to Step 4.
(b) If NOT OK, check fuse 8 in fuse block and
the 30 Amp maxi fuse in the Power Distribution
Center (PDC). If fuses are OK, check wiring cir-
cuit. Refer to Group 8W, Wiring Diagrams.
(4) Check Pin 5, with switch in the ON position
there should be battery voltage and no voltage in the
OFF position.
(a) If OK, go to Step 5.
(b) If NOT OK, no voltage in the ON position or
voltage in the OFF position. Replace the switch/re-
lay module.
(5) Press switch to ON position. The indicator
lamp should come on and remain on for approxi-
mately 10 minutes. If the indicator lamp fails to light
or no voltage is present for approximately 10 min-
utes. Replace Rear Window Defogger Switch.
(6) To bench test relay:
(a) Using a jumper wire connect a 12 volt batter
supply, apply voltage to Pin 3 and 4. Ground Pin 2.
(b) Follow the above procedures except Step 2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING; CALL A PHYSICIAN
IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH
WITH PLENTY OF WATER. USE WITH ADEQUATEVENTILATION. DO NOT USE NEAR FIRE OR FLAME.
CONTENTS CONTAIN 3 PERCENT FLAMMABLE
SOLVENTS.
KEEP OUT OF REACH OF CHILDREN.
The repair of the grid lines or the terminal is pos-
sible using the MopartRepair Package or equiva-
lent.
(1) Mask repair area so conductive epoxy can be
extended onto the line or the bus bar (Fig. 5).
(2) Follow instructions in repair kit for preparing
damaged area.
(3) Remove package separator clamp and mix plas-
tic conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy.
(4) For grid line, mark off area to be repaired with
masking tape or a template (Fig. 5).
(5) Apply conductive epoxy through slit in masking
tape. Overlap both ends of the break by 19 mm (3/4
inch).
(6) For a terminal or pigtail replacement, mask
adjacent areas so epoxy can be extended onto line as
well as bus bar. Apply a thin layer of epoxy to area
where terminal was fastened and to adjacent line.
(7) Apply a thin layer of conductive epoxy on ter-
minal and place terminal on desired location. To pre-
vent terminal from moving while the epoxy is curing,
it must be wedged or clamped.
(8) Carefully remove masking tape from grid line.
CAUTION: Do not allow the glass surface to
exceed 204ÉC (400ÉF), glass may fracture.
(9) Allow epoxy to cure 24 hours at room tempera-
ture or use heat gun with a 260Éto 371ÉC (500É to
700ÉF) range for 15 minutes. Hold gun approximately
254 mm (10 inches) from repaired area.
(10) After conductive epoxy is properly cured
remove wedge from terminal and check out operation
of rear window defogger. Do not attach connectors
until curing is complete.
Fig. 4 Rear Window Defogger Switch
Fig. 5 Grid Line Repair
PLELECTRICALLY HEATED SYSTEMS 8N - 3
DIAGNOSIS AND TESTING (Continued)

ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH....... 1REMOVAL AND INSTALLATION
REAR WINDOW DEFOGGER AND/OR REAR
FOG LAMP SWITCH................... 2
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch may be tested in-
vehicle or bench tested. In vehicle testing is accom-
plished in the following manner:
(1) Remove the switch from the instrument panel
but leave the switch connected, refer to Group 8E,
Instrument Panel and Systems for removal proce-
dures.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, check for battery voltage at
Pin 3 and Pin 4 (Fig. 1) and (Fig. 2).
(a) If OK, go to Step 4.
(b) If NOT OK, check fuse 8 in fuse block and
the 30 Amp maxi fuse in the Power Distribution
Center (PDC). If fuses are OK, check wiring cir-
cuit. Refer to Group 8W, Wiring Diagrams.
(4) Check Pin 5, with switch in the ON position
there should be battery voltage and no voltage in the
OFF position.
(a) If OK, go to Step 5.
(b) If NOT OK, no voltage in the ON position or
voltage in the OFF position. Replace the switch/re-
lay module.
(5) Press switch to ON position. The indicator
lamp should come on and remain on for approxi-
mately 10 minutes. If the indicator lamp fails to light
or no voltage is present for approximately 10 min-
utes. Replace Rear Window Defogger Switch.
(6) To bench test relay:
(a) Using a jumper wire connect a 12 volt batter
supply, apply voltage to Pin 3 and 4. Ground Pin 2.
(b) Follow the above procedures except Step 2
Fig. 1 Systems Electrical Circuit
PLELECTRICALLY HEATED SYSTEMS 8N - 1