windshield wipers DODGE NEON 1999 Service Repair Manual

WINDSHIELD WIPERS AND WASHERS
CONTENTS
page page
WINDSHIELD WASHER SYSTEM............. 8WINDSHIELD WIPERS..................... 1
WINDSHIELD WIPERS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
WIPER BLADES.......................... 1
DIAGNOSIS AND TESTING
WINDSHIELD WIPER CONDITION............ 2
WIPER MOTOR.......................... 3
WIPER SWITCH.......................... 5
REMOVAL AND INSTALLATION
WIPER ARM............................. 5WIPER BLADE ELEMENT.................. 5
WIPER BLADE........................... 5
WIPER LINKAGE......................... 6
WIPER MODULE......................... 6
WIPER MOTOR.......................... 6
WIPER SWITCH.......................... 6
CLEANING AND INSPECTION
WIPER BLADES.......................... 6
ADJUSTMENTS
WIPER ARM ADJUSTMENT................. 7
GENERAL INFORMATION
INTRODUCTION
WARNING: VEHICLES ARE EQUIPPED WITH AN
AIRBAG, REFER TO GROUP 8M, RESTRAINT SYS-
TEMS FOR STEERING WHEEL OR COLUMN SER-
VICE PROCEDURES.
The windshield wipers will only operate with the
ignition switch in the ACCESSORY or IGNITION
RUN position. The wiper circuit is protect against
over loads by a fuse in the fuse block and a circuit
breaker within the wiper motor. This protects the cir-
cuitry of the wiper system and the vehicle.
The wiper motor has permanent magnet fields.
The intermittent wiper system, in addition to low
and high speed, has a delay mode and a pulse wipe
mode. The delay mode has a range of 1 to 15 seconds.
Pulse wipe is accomplished by momentarily moving
the stalk lever into the WASH position while the
wiper switch is in either OFF or DELAY position.
The wiper blades then sweep once or twice and
return to the previous wiper switch mode, OFF or
DELAY.The intermittent wiper function is integral to the
wiper switch. All electronics and relay are inside the
switch assembly.
The wiper system completes the wipe cycle when
the switch is turned OFF. The blades park in the
lowest portion of the wipe pattern.
DESCRIPTION AND OPERATION
WIPER BLADES
Wiper blades, exposed to the weather for a long
period of time, tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is suggested to
remove the accumulation of salt and road film. The
wiper blades, arms, and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the blades continue to
streak or smear, they should be replaced. The right
and left wipers are different blade lengths. The
driver side length is 525 mm and the passenger side
length is 450 mm. The blades should not be inter-
changed.
PLWINDSHIELD WIPERS AND WASHERS 8K - 1

DIAGNOSIS AND TESTING
WINDSHIELD WIPER CONDITION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
STEERING WHEEL OR COLUMN REMOVAL PROCE-
DURES.
The following is a list of general wiper motor sys-
tem problems, the tests that are to be performed to
locate the faulty part, and the corrective action to be
taken.
Whatever the problem, disconnect motor wire har-
ness and clean the terminals, then connect motor
wire harness and test.
MOTOR WILL NOT OPERATE IN SOME OR ALL
SWITCH POSITIONS
(1) Check fuse 15, in the fuse block (Fig. 1).
(a) If fuse is OK, go to Step 2.
(b) If fuse is defective, replace and check motor
operation in all switch positions.
(c) If motor is still inoperative and the fuse does
not blow, go to Step 2.
(d) If replacement fuse blows, go to Step 6.
(2) Disconnect motor wire connector.
(3) Check motor low speed. Using two jumper
wires, connect one jumper wire between the battery
positive terminal and terminal 2 of the motor connec-
tor. Connect the other jumper wire to the battery
negative terminal and the motor ground strap. Refer
to Wiper Motor Connector Pinout table and (Fig. 2).
Check motor high speed, connect the positive jumper
wire to terminal 1 of the motor connector. Connect
the negative jumper wire to the motor ground strap.
(a) If motor does not run, high or low speed go to
Step 4.
(b) If motor runs, go to Step 5.(4) Using an ohmmeter, check for good ground at
the motor ground strap. If OK, replace motor. If not
repair the ground circuit as necessary.
(5) Check terminal E of wiper switch connector for
continuity to ground. If OK, go to Step 6. If not OK,
repair the ground circuit as necessary.
(6) Using a voltmeter, with wiper switch con-
nected, connect negative lead to motor ground strap.
Connect the positive lead to terminal P1 of the wiper
switch connector (Fig. 3) and (Fig. 5).
(a) If no voltage, repair wiring as necessary. If
OK, go to Step 2.
(b) Check wiper switch low speed, connect volt-
meter positive lead to terminal L of the wiper
switch connector. Move wiper stalk to LOW posi-
tion. If no voltage, replace switch.
(c) Check wiper switch high speed, connect volt-
meter positive lead to terminal H of the wiper
switch connector. Move wiper stalk to HIGH posi-
tion. If no voltage, replace switch.
(7) Disconnect motor connector and replace fuse 15
in fuse block.
(a) If fuse does not blow, replace motor.
Fig. 1 Fuse Block
WIPER MOTOR CONNECTOR PINOUT
CAVITY FUNCTION
1 WIPER SWITCH HIGH SPEED
OUTPUT
2 SIPER SWITCH LOW SPEED
OUTPUT
3 WIPER RELAY COMMON
4 FUSED IGNITION SWITCH OUTPUT
(RUN/ACC.)
Fig. 2 Windshield Wiper Motor Connector
8K - 2 WINDSHIELD WIPERS AND WASHERSPL

(b) If fuse blows, disconnect wiper switch and
replace fuse.
(c) If fuse does not blow, replace switch.
(d) If fuse blows, repair wiring as necessary.
MOTOR OPERATES SLOWLY AT ALL SPEEDS
(1) Remove wiper arms and cowl screen. Discon-
nect motor linkage from motor. Connect an ammeter
between battery positive terminal and terminal 4 of
the motor connector (Fig. 4). Turn wiper motor on
and check ampere reading.
If motor runs and ammeter reading is more than 6
amps, go to Step 2. If less than 6 amps, go to Step 3.
When replacing drive link nut tighten to 11 to 12
N´m (98 to 106 in. lbs.) torque.(2) Using an ohmmeter, check the high and low
circuits for a short to ground. Refer to Group 8W,
Wiring Diagrams.
(3) Check to see if wiper linkage or pivots are
binding or caught.
WIPERS RUN AT HIGH SPEED WITH SWITCH
IN LOW SPEED POSITION OR WIPERS RUN AT
LOW SPEED WITH SWITCH IN HIGH SPEED
POSITION.
(1) Check for crossed wires in the motor pigtail
wire connector. Refer to Group 8W, Wiring Diagrams.
(2) Check for crossed wires in harness connector
from wiper switch to motor.
(3) If OK, replace wiper switch.
WIPERS WILL OPERATE CONTINUOUSLY
WITH SWITCH IN THE INTERMITTENT
POSITIONÐWHEN WIPER SWITCH IS TURNED
OFF, WIPERS STOP WHEREVER THEY ARE,
WITHOUT RETURNING TO PARK POSITION.
(1) Check at motor ground strap for a good ground.
(2) Turn ignition switch OFF. Using an ohmmeter,
with the motor in the park position, check for conti-
nuity between terminal 3 and ground strap. If conti-
nuity, replace wiper switch. If no continuity, repair
wiring as necessary.
WIPERS DO NOT OPERATE WHEN WASHER
MOTOR IS ENGAGED (PULSE WIPE) OR
WIPERS DO OPERATE IN INTERMITTENT
POSITION.
Check for a good ground at motor ground strap and
at wiper switch terminal E. If OK, replace wiper
switch. If not OK, repair wiring as necessary.
WIPER MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
STEERING WHEEL OR COLUMN REMOVAL PROCE-
DURES.
Whenever a wiper motor malfunction occurs, verify
that the wire harness is properly connected start nor-
mal diagnosis and repair procedures. Refer to Wiper
System Diagnosis.
Fig. 3 Wiper Switch and Terminals
Fig. 4 Ammeter Test
PLWINDSHIELD WIPERS AND WASHERS 8K - 3
DIAGNOSIS AND TESTING (Continued)

WIPER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WIPER BLADES DO NOT
PARK PROPERLY1. WIPER ARMS
IMPROPERLY PARKED.
2. WIPER ARMS ARE
LOOSE ON PIVOT SHAFT.
3. MOTOR CRANK LOOSE
AT OUTPUT SHAFT.1. REMOVE WIPER ARMS AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
2. REMOVE WIPER ARM AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
3. REMOVE WIPER ARM, RUN WIPER
MOTOR TO PARK POSITION AND REMOVE
THE MODULE. WITHOUT ROTATING THE
MOTOR OUTPUT SHAFT, REMOVE THE
CRANK AND CLEAN ANY FOREIGN MATTER
FROM THE MOTOR SHAFT. INSTALL THE
MOTOR CRANK IN ITS ORIGINAL POSITION.
MOTOR STOPS IN ANY
POSITION WHEN THE
SWITCH IS TURNED OFF1. OPEN PARK CIRCUIT. 1. CHECK PARK SWITCH BY
DISCONNECTING THE WIRE CONNECTOR
AND APPLY BATTERY VOLTAGE TO PIN 4.
PLACE A JUMPER WIRE FROM PIN 2 TO
PIN 3 AND THEN TO AN EXTERNAL
GROUND. REPLACE MOTOR IF IT DOES
NOT PARK.
MOTOR WILL NOT STOP
WHEN THE SWITCH IS
TURNED OFF1. FAULTY SWITCH.
2. LOCK OF DYNAMIC
BRAKE ON WET GLASS.1. CHECK SWITCH IN LOW, HIGH AND
INTERMITTENT POSITION.
2. ENSURE PARK SWITCH HAS CLEAN
GROUND.
WIPER BLADES SLAP
AGAINST COWL SCREEN
OR WINDOW MOLDINGS.1. WIPER ARMS ARE
PARKED INCORRECTLY.1. PARK WIPER ARMS. REFER TO WIPER
ARM ADJUSTMENT.
BLADES CHATTER 1. FOREIGN SUBSTANCE
SUCH AS POLISH ON
GLASS OR BLADES.
2. ARMS TWISTED, BLADE
AT WRONG ANGLE ON
GLASS.
3. BLADE STRUCTURE
BENT.
4. BLADE ELEMENT HAS
PERMANENT SET.1. CLEAN GLASS AND BLADE ELEMENT
WITH NON-ABRASIVE CLEANER.
2. REPLACE ARM.
3. REPLACE BLADE.
4. REPLACE BLADE ELEMENT.
WIPER KNOCK AT
REVERSAL1. LINKAGE BUSHINGS
WORN.
2. ARMATURE ENDPLAY IN
MOTOR.1. REPLACE WORN LINK. REFER TO WIPER
LINKAGE REMOVAL AND INSTALLATION.
2. REPLACE WIPER MOTOR. REFER TO
WIPER MOTOR REMOVAL AND
INSTALLATION.
WIPER MOTOR WILL NOT
RUN1. BLOWN FUSE.
2. NEW FUSE BLOWS.
3. NEW FUSE BLOWS.
4. NO VOLTAGE AT MOTOR.
5. POOR GROUND.1. REPLACE FUSE, AND RUN SYSTEM.
2. CHECK FOR SHORT IN WIRING OR
SWITCH.
3. REPLACE FUSE, REMOVE MOTOR
CONNECTOR, TURN SWITCH ON, FUSE
DOES NOT BLOW, REPLACE MOTOR.
4. CHECK SWITCH AND WIRING HARNESS.
REFER TO GROUP 8W, WIRING DIAGRAMS.
5. REPAIR GROUND WIRE CONNECTION AS
NECESSARY.
8K - 4 WINDSHIELD WIPERS AND WASHERSPL
DIAGNOSIS AND TESTING (Continued)

WIPER SWITCH
To test the switch, first disconnect the switch wires
from the body wiring in the steering column. Using
an ohmmeter, test for continuity between the termi-
nals of the switch, as indicated in the following con-
tinuity chart (Fig. 5).
REMOVAL AND INSTALLATION
WIPER ARM
REMOVAL
(1) Place the wiper arm/blades in the PARK posi-
tion and turn ignition OFF.
(2) Remove arm cap and wiper arm nut.
(3) Remove the arm from the pivot using a rocking
motion.
(4) Clean metal splinters OFF the pivot shafts.
INSTALLATION
For installation reverse above procedures. Before
installation activate wiper system to ensure the
wiper module is in the PARK position. Position wiper
arms so that the heel of the blade(s) is on the park
line on the windshield.
WIPER BLADE
REMOVAL
(1) Lift wiper arm to over center position.
(2) Remove blade assembly from arm by pushing
release tab under arm tip and slide blade away from
arm tip (Fig. 6) and (Fig. 7).
(3) Gently place wiper arm tip on glass surface.
INSTALLATION
For installation reverse above procedures.
WIPER BLADE ELEMENT
REMOVAL
(1) Lift wiper arm to raise blade off glass.
(2) Remove blade assembly from arm by pushing
release tab under arm tip and slide blade away from
arm tip (Fig. 6) and (Fig. 7). Gently place wiper arm
tip on glass surface.
(3) Remove wiping element from blade assembly.
Pull stopper, of the rubber element, out of the end
claw together with vertibra (metal rails) (Fig. 8).
INSTALLATION
For installation reverse the above procedures.
Check that the element and vertibra are through all
claws and the final claw is locked in the stopper.
Fig. 5 Wiper Switch Test
Fig. 6 Wiper Blade and Element
Fig. 7 Remove Blade from Arm
Fig. 8 Wiper Blade and Element
PLWINDSHIELD WIPERS AND WASHERS 8K - 5
DIAGNOSIS AND TESTING (Continued)

WIPER LINKAGE
REMOVAL
(1) Remove wiper module refer above (Fig. 9).
(2) Disconnect wiper arm linkage, by insert screw-
driver between ball cap and linkage, then twist the
screwdriver and lift straight up on linkage.
INSTALLATION
For installation reverse the above procedures.
Using pliers or hand press the ball cap straight on to
the ball stud.
WIPER MODULE
REMOVAL
(1) Remove wiper arms and blades (Fig. 9).
(2) Remove the rear hood seal with the cowl top
plastic screen.
(3) Disconnect motor wire connector at front ple-
num wall.
(4) Remove wiper module mounting screws and
remove module.
INSTALLATION
For installation reverse the above procedures.
Tighten the mounting screws to 7 to 9 N´m (60 to 80
in. lbs.) torque.
WIPER MOTOR
REMOVAL
(1) Remove wiper module refer above.
(2) Remove linkage from motor crank. Insert
screwdriver between crank and linkage then twist
the screwdriver and lift straight up on linkage.(3) Remove motor mounting screws and remove
motor.
INSTALLATION
For installation add unilube grease to socket and
reverse the above procedures. Tighten the motor
mounting screws to 5 to 6 N´m (45 to 55 in. lbs.)
torque. Tighten drive link nut to 11 to 12 N´m (98 to
106 in. lbs.) torque.
WIPER SWITCH
REMOVAL
(1) Remove three screws holding steering column
shroud and remove upper half of shroud (Fig. 10).
(2) Remove mounting screw on switch and remove
switch.
(3) Disconnect wire harness connector from switch.
INSTALLATION
For installation, reverse the above procedures.
CLEANING AND INSPECTION
WIPER BLADES
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. The
wiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
Fig. 9 Wiper Motor and Linkage Module
Fig. 10 Upper Shroud Removal
8K - 6 WINDSHIELD WIPERS AND WASHERSPL
REMOVAL AND INSTALLATION (Continued)

arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, refer to the
Wiper Arm Alignment paragraph of this group.
ADJUSTMENTS
WIPER ARM ADJUSTMENT
(1) Cycle the wiper motor into the PARK position.
(2) Lift the wiper blade off the windshield and
release it.
(3) The wiper blade heel should be parked within 5
mm of the park line. The park line is mark on the
windshield (Fig. 11).
(4) In the event that the wiper blade tip exces-
sively strikes the cowl screen due to long term nor-
mal wear, reposition the wiper blade heel slightlyabove the park line. Make sure that the wipers are
in the PARK position.
Fig. 11 Arm Adjustment
PLWINDSHIELD WIPERS AND WASHERS 8K - 7
CLEANING AND INSPECTION (Continued)

WINDSHIELD WASHER SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
WASHER NOZZLE........................ 8
DIAGNOSIS AND TESTING
WINDSHIELD WASHERS................... 8REMOVAL AND INSTALLATION
WASHER NOZZLE........................ 9
WASHER RESERVOIR PUMP.............. 10
WASHER RESERVOIR..................... 9
DESCRIPTION AND OPERATION
WASHER NOZZLE
This model is equipped with two hood mounted
washer nozzles. Each nozzle emits two streams into
the wiper pattern (Fig. 1). If the nozzle performance
is unsatisfactory they can be adjusted. To adjust
insert a pin into the nozzle ball and move to proper
pattern (Fig. 2). The right and left nozzles are iden-
tical.
DIAGNOSIS AND TESTING
WINDSHIELD WASHERS
All models are equipped with electric operated
windshield washer pumps.
The wash function can be accessed in the OFF
position of the wiper control switch. Holding the
wash button depressed when the switch is in the
OFF position will operate the wipers and washer
motor pump continuously until the washer button is
released. Releasing the button will stop the washer
pump but the wipers will complete the current wipe
cycle. Followed by an average of two more wipe
cycles (61) before the wipers park and the module
turns off.
Whenever a windshield washer malfunction occurs,
first verify that the windshield washer wire harness
is properly connected to all connectors before starting
normal diagnosis and repair procedures. Refer to
Windshield Washer Test Table.
The electric pump assembly is mounted directly to
the reservoir. A permanently lubricated motor is cou-
pled to a rotor type pump. Fluid, gravity fed from the
reservoir, is forced by the pump through rubber hoses
to the hood mounted nozzles which direct the fluid
streams to the windshield.
The pump and reservoir are serviced as separate
assemblies (Fig. 3).
Fig. 1 Windshield Washer Nozzle
Fig. 2 Windshield Washer Pattern
8K - 8 WINDSHIELD WIPERS AND WASHERSPL

REMOVAL AND INSTALLATION
WASHER NOZZLE
REMOVAL
(1) Disconnect washer fluid hose at the nozzle.
(2) Using a needle nose pliers, squeeze together
the locking tabs on the nozzle (Fig. 1).
(3) Remove nozzle.
INSTALLATION
(1) Place the nozzle in position and push down-
ward till locking tabs are securely snapped into posi-
tion.
(2) Connect the washer hose and ensure that the
hose is not kinked.
WASHER RESERVOIR
REMOVAL
(1) Remove filler neck (Fig. 4).
(2) Raise vehicle on hoist.
(3) Disconnect the wire connector from the reser-
voir pump (Fig. 5).
(4) Disconnect the washer hose at the pump and
drain the reservoir.
(5) Remove fastener from reservoir.
(6) Remove the reservoir through fender opening.
INSTALLATION
For installation, reverse the above procedures.
Tighten the reservoir screw to 2.2 to 3.3 N´m (20 to
29 in. lbs.) torque.
WINDSHIELD WASHER TEST TABLE
CONDITION POSSIBLE CAUSE CORRECTION
PUMP RUNS, NO FLUID
FLOWING1) NO FLUID IN THE
RESERVOIR.
2) NOZZLE PLUGGED OR
FROZEN.
3) BROKEN, LOOSE OR
PINCHED HOSE.
4) FAULTY PUMP.HOSE.1) FILL RESERVOIR.
2) THAW AND CHECK FLOW. IF BLOCKED,
REPLACE AS NECESSARY.
3) CHECK FLOW THROUGH HOSE
CONNECTIONS.
4) APPLY BATTERY VOLTAGE TO MOTOR
TERMINALS. REPLACE IF PUMP DOES NOT
RUN.
SYSTEM OPERATES
INTERMITTANTLY1) LOOSE WIRE
CONNECTION.
2) FAULTY SWITCH.1) CHECK WIRE CONNECTIONS.
2) DISCONNECT WIRE HARNESS, USE
VOLTMETER TO CHECK SWITCH.
SYSTEM OUTPUT IS LOW 1) PINCHED HOSE.
2) HOSE BLOCKED.1) CHECK FLOW THROUGH HOSE
CONNECTION.
2) DISCONNECT HOSE AT NOZZLE AND9Y9
CONNECTOR. CHECK FOR FLOW.
REPLACE AS NECESSARY.
Fig. 3 Washer Fluid Reservoir
Fig. 4 Filler Neck Removal
PLWINDSHIELD WIPERS AND WASHERS 8K - 9
DIAGNOSIS AND TESTING (Continued)

WASHER RESERVOIR PUMP
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the wire connector from the reser-
voir pump.(3) Disconnect the washer hose at the pump and
drain the reservoir.
(4) Gently pry pump away from reservoir and out
of grommet. Care must be taken not to puncture res-
ervoir (Fig. 6).
(5) Remover rubber grommet from reservoir and
throw away.
INSTALLATION
For installation, reverse the above procedures.
Fig. 5 Reservoir Removal
Fig. 6 Washer Pump
8K - 10 WINDSHIELD WIPERS AND WASHERSPL
REMOVAL AND INSTALLATION (Continued)