fuse box diagram DODGE NEON 1999 Service Repair 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)

(3) Close all doors, windows and vents to the pas-
senger compartment.
(4) Set Heater-A/C control to A/C, full heat, floor,
RECIRC. and high blower.
(5) Start the engine and hold the idle speed (1000
rpm). After the engine has reached running temper-
ature, allow the passenger compartment to heat up.
This will create the need for maximum refrigerant
flow into the evaporator.
(6) If the refrigerant charge is sufficient, discharge
(high pressure) gauge should read 965 to 2620 kPa
(140 to 380 psi). Suction (low pressure) gauge should
read 103 to 2417 kPa (15 to 35 psi). If system cannot
achieve proper pressure readings, replace the expan-
sion valve. If pressure is correct, proceed with test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(7) If suction side low pressure is within specified
range, freeze the expansion valve control head (Fig.
10) for 30 seconds. Use a super cold substance (liquid
CO2).Do not spray refrigerant on the expansion
valve for this test.Suction side low pressure should
drop to 34.5 kPa (5 psi) If not, replace expansion
valve.
(8) Allow expansion valve to thaw. The low pres-
sure gauge reading should stabilize at 103 to 241
kPa (15 to 35 psi). If not, replace expansion valve.
(9) When expansion valve test is complete, test
A/C overall performance. Refer to the Heater and A/C
Performance Test in this section. Remove all test
equipment before returning vehicle to use.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
Refer to the Blower Motor Electrical System Diag-
nosis chart in this section. Also refer to Group 8W,
Wiring Diagrams for more information.
BLOWER MOTOR VIBRATION AND/OR NOISE
DIAGNOSIS
The resistor block supplies the blower motor with
varied voltage (low and middle speeds) or battery
voltage (high speed).
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater-A/C
housing.
Refer to the Blower Motor Vibration/Noise chart
for diagnosis.
EVAPORATOR PROBE TEST
The work area and vehicle must be between 16É C
(60É F) and 32É C (90É F) when testing the switch.(1) Disconnect the three wire connector from the
evaporator probe lead located behind the glove box.
(2) Start engine and set A/C to low blower motor
speed, panel, full cool, and RECIRC.
(3) Using a voltmeter, check for battery voltage
between Pin 1 and 2. If no voltage is detected, there
is no power to the switch. Check wiring and fuses.
Refer to Group 8W, Wiring Diagrams for circuit diag-
nosis.
(4) Using a voltmeter, check for battery voltage
between Pin 1 and Pin 3. If no voltage is detected,
there is no voltage from the Powertrain Control Mod-
ule. Refer to Group 8W, Wiring Diagrams. If voltage
is OK, connect a jumper wire between Pin 1 and Pin
3. The compressor clutch should engage. If the clutch
engages, remove the jumper wire immediately and go
to Step 5. If the compressor clutch does not engage,
check the operation of the clutch and repair as nec-
essary.
(5) If compressor clutch engages, connect the evap-
orator probe 3-way connector. The compressor clutch
should engage or cycle depending on evaporator tem-
perature. If OK, go to Step 6. If not OK, replace the
clutch cycling switch.
(6) The engine running and the A/C set to:
²Blower motor on low speed
²Panel position
²Full cool
²RECIRC.
Close all doors and windows. Place a thermometer
in the center discharge vent.
(7) If the clutch does not begin to cycle off between
2É C to 7É C (35É F to 45É F), verify that the evapo-
rator probe is fully installed and not loose in evapo-
rator. If it is not properly installed, install probe and
retest outlet temperature. If the evaporator probe is
properly installed, replace the clutch cycling switch.
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
Review Safety Precautions and Warnings in this
group before performing the following procedures.
Check the coolant level, drive belt tension, vacuum
line connections, radiator air flow and fan operation.
Start engine and allow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing cap. Place a rag over the cap and
turn it to the first safety stop. Allow pressure to
escape through the overflow tube. When the system
stabilizes, remove the cap completely.
24 - 8 HEATING AND AIR CONDITIONINGPL
DIAGNOSIS AND TESTING (Continued)