light DODGE NEON 2000 Service Repair Manual

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................8W-80-4
A/C Cycling Switch...................8W-80-4
A/C Heater Blower Motor..............8W-80-4
A/C Heater Control...................8W-80-4
A/C High Pressure Switch.............8W-80-4
A/C Low Pressure Switch..............8W-80-5
Airbag Control Module................8W-80-5
Back-Up Lamp Switch................8W-80-5
Blower Motor Resistor Block...........8W-80-6
Brake Lamp Switch..................8W-80-6
Brake Shift Interlock Solenoid..........8W-80-6
Brake Warning Indicator Switch........8W-80-6
C101..............................8W-80-7
C102..............................8W-80-7
C103..............................8W-80-8
C104..............................8W-80-9
C105.............................8W-80-10
C106.............................8W-80-10
C107.............................8W-80-10
C108.............................8W-80-10
C109.............................8W-80-11
C110 .............................8W-80-11
C111 .............................8W-80-11
C201.............................8W-80-12
C202.............................8W-80-13
C203.............................8W-80-13
C204.............................8W-80-13
C205.............................8W-80-14
C301.............................8W-80-15
C302.............................8W-80-15Component Page
C303.............................8W-80-15
C304.............................8W-80-15
C305..........................8W-80-16, 17
C306.............................8W-80-17
Camshaft Position Sensor.............8W-80-18
Cargo Lamp.......................8W-80-18
Center High Mounted Stop Lamp.......8W-80-18
Center Stack Lamp..................8W-80-18
Cigar Lighter/Power Outlet............8W-80-18
Clockspring........................8W-80-19
Clutch Interlock Switch..............8W-80-19
Controller Anti-Lock Brake............8W-80-19
Crankshaft Position Sensor............8W-80-20
Data Link Connector.................8W-80-20
Decklid Solenoid....................8W-80-20
Dome Lamp.......................8W-80-20
Dome Lamp/Intrusion Sensor..........8W-80-21
Driver Airbag......................8W-80-21
Driver Cylinder Lock Switch...........8W-80-21
Driver Door Lock Motor..............8W-80-21
Driver Door Lock Switch..............8W-80-21
Driver Power Mirror.................8W-80-22
Driver Power Window Motor...........8W-80-22
Driver Power Window Switch..........8W-80-23
Engine Coolant Temperature Sensor.....8W-80-23
Engine Oil Pressure Switch...........8W-80-24
Fuel Injector No. 1..................8W-80-24
Fuel Injector No. 2..................8W-80-24
Fuel Injector No. 3..................8W-80-24
Fuel Injector No. 4..................8W-80-24
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

- - -
- - - V32 20YL/RD
Z1 18BK
Z12 18BK/TN G7 20WT/OR
T40 14BR F12 18DB/WT
1411
12
13
9C20 20BR/OR
5
6
8 7 3
4 2 1CIRCUIT CAV
10 7
14 81
C102C102
10
CAV CIRCUIT
1
2
4 3
7
8 6 5
9
13 1211
14-
-
- -
-
- 147 1
8
-
SPEED CONTROL
C20 18BR/OR
F12 18DB/WT
T40 14BR G7 20WT/OR
Z12 18BK/TN V32 20YL/RD
- - - -
- - - K22 20OR/DB
K90 20TN
K141 20TN/WT K119 18LG/BK K6 18VT/WT
K7 20OR K4 20BK/LB
1411
12
13
9A142 18DG/OR
5
6
8 7 3
4 2 1CIRCUIT CAV
10 7
14 81
C101C101
10
CAV CIRCUIT
1
2
4 3
7
8 6 5A142 18DG/OR
9
13 1211
14K4 18BK/LB
K7 20OR K6 18VT/WT
K119 20LG/BK
K141 20TN/WT K90 20TN K22 20OR/DB
-
-
- -
-
- 147 1
8
2.0L
MTX
BLACKBLACK
LIGHT GRAYLIGHT GRAY
Z1 18BK
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7
PLI08007008W-10

C203
C203
LIGHT
3 1
6 4LIGHT GRAY
14BK/TN C7 6- 5
14DG C1 4
22DB/OR C21 3
22WT F20 2
22DB/YL C2 1
CIRCUIT CAV
14BK/TN C7 6- 5
14DG C1 4
22DB/OR C21 3
20WT F20 2
22DB/YL C2 1
CIRCUIT CAVGRAY
A/C
64
3
1
Z3 18BK/OR M2 18YL
M1 20PK
-
-
- -
4
6
3
1M1 18BK/PK
M2 18BK/YL
Z3 18BK/ORCAV CIRCUIT
1
2
4 3
6 5
C204
5
6 3
4 2 1CIRCUIT CAV
C204C202
10 CAV CIRCUIT
1
2
4 3
7
8 6 5
9-
C5 14LG
C202
1 5
6
10
9 5
6
8 7 3
4 2 1CIRCUIT CAV
10 105
1
6
C4 14TN C7 14BK/TN C6 14LB
Z1 16BK V6 16DB V5 16DG/YL V3 16BR/WT
V4 16RD/YL
V4 16RD/YL
V3 16BR/WT
V5 16DG/YL
V6 16DB
Z1 16BK
C6 14LB
C7 14BK/TN
C4 14TN
C5 14LG
-
4 1
63
POWER SUNROOF
F10 18YL/RD F10 18YL/RD
REDRED
LIGHT GREENLIGHT GREEN
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13
PLI08013008W-10

CAV CIRCUIT FUNCTION
1 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
BLACK
1 2
3 CAV
2 1
CIRCUIT
GROUND FUSED IGNITION SWITCH OUTPUT (RUN-ACC)FUNCTION
--
2
3
1REDF30 16RD
Z1 16BK
LAMP MOUNTED STOPCENTER HIGH
CIGAR LIGHTER/
POWER OUTLET
BLACK
CAV CIRCUIT FUNCTION
1 M1 20PK FUSED B(+)
2 G78 22TN/BK DECKLID AJAR SWITCH SENSE
CARGO
LAMP
GROUND 2Z1 20BK
SENSOR CAMSHAFT POSITION
BLACK
1 3
CAMSHAFT POSITION SENSOR SIGNAL 20TN/YL K44 3SENSOR GROUND 20BK/LB K4 2
8V SUPPLY 20OR K7 1
FUNCTION CIRCUIT CAV
LAMP CENTER STACK
GROUND Z3 20BK/OR 2PANEL LAMPS DRIVER E2 20OR 1
FUNCTION CIRCUIT CAV1 2BLACK
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTSPL
008W-10PLI08018

LHD
RHD
Z2 22BK/LGGROUND
F9 20RD/BKFUSED B(+)
PASSENGER DOOR SWITCH MUX
P96 20LG/BK
- -
L7 20BK/YLDIMMER SWITCH LOW BEAM OUTPUT
REMOTE KEYLESS
ENTRY MODULE
1411
12
13
9 5
6
8 7 3
4 2 1CIRCUIT CAV
10
21 15
18
19 17 16
20
24 23 22
25
26
F35 18RDHEADLAMP SWITCH OUTPUT
P33 18OR/BKFUSED B(+)
P34 18PK/BKDOOR LOCK DRIVER
P36 18PK/VTDOOR UNLOCK DRIVER
M9 20DB/ORDOOR UNLOCK DRIVER
PASSENGER DOOR AJAR/ RKE SENSE
P97 20LGDRIVER DOOR SWITCH MUX
Z1 20BKGROUND
X161 20WTRKE ANTENNA
X5 22WT/RDDISPLAY BACKLIGHT
Q2 16LG/BKDECKLID RELEASE RELAY OUTPUT
G69 20BK/ORVTSS INDICATOR DRIVER
X3 22BK/RDHORN RELAY CONTROL
D25 20VT/YLPCI BUS
G120 18WT/BKINTRUSION SENSOR SIGNAL
M1 20PKFUSED B(+)
G5 20DB/WTFUSED IGNITION SWITCH OUTPUT (ST-RUN)
G70 20BR/TNHOOD AJAR SWITCH SENSE
G71 20VT/YLDECKLID SECURITY SWITCH SENSE
G75 18TNDRIVER DOOR AJAR SWITCH SENSE
X161 20WTJAPAN ANTENNA L4 16VT/WT
BUILT-UP-EXPORT
1
13
14
26REAR WINDOW DEFOGGER RELAY OUTPUT
C15 12BKPANEL LAMPS DRIVER
E2 20OR Z2 22BK/LGGROUND F20 20WTFUSED IGNITION SWITCH OUTPUT (RUN) A4 12BK/RDFUSED B(+)
SWITCH
51
DEFOGGER REAR WINDOW
FUNCTION
CAV CIRCUIT
1
2
4 3
5
F35 18RD/YL
FUSED B(+) 3
5
C15 12BK/WTRAER WINDOW DEFOGGER RELAY OUTPUT
INTRUSION SENSOR SIGNAL
G120 18WT/DB20
BLACK
BLACK
FUNCTION
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTSPL
J008W-10PLI08040

CAV CIRCUIT FUNCTION
1
Z1 18BK GROUND
2
L7 18BK/YL HEADLAMP SWITCH OUTPUT
3 L62 18BR/RD RIGHT TURN SIGNAL
RIGHT TAIL/STOP/
TURN SIGNAL LAMP
SEAT BELT SWITCH
1 2
BLACK
SEAT BELT SWITCH SENSE 20LG/RD G10 1
GROUND 18BK Z1 2
FUNCTION CIRCUIT CAV
(EXCEPT BUILT-UP-EXPORT)
M1 20PKFUSED B(+) GROUND
Z1 18BK X5 20WT/RDDISPLAY BACKLIGHT
4
1
SIREN
DISPLAY BACKLIGHT
X5 20WT/RDFUNCTION
CAV CIRCUIT
1
2
4 3
MODULE IMMOBILIZER
- -- -
FUSED B(+)
M1 20PKGROUND
Z2 20BK/LGFUSED IGNITION SWITCH OUTPUT (ST-RUN)
G5 20DB/WTPCI BUS D25 22VT/YL1
6
SENTRY KEY
FUNCTION
CAV CIRCUIT
1
2
4 3
6 5
RIGHT TAIL/STOP
LAMP
(BUILT-UP-EXPORT)
1 3
HEADLAMP SWITCH OUTPUTGROUND Z1 18BK
3
CAV CIRCUIT FUNCTION
1
L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK/YL
(BUILT-UP-EXPORT)
31
BLACK
BLACK
BLACK
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
PLI08045008W-10

Connector
Name/NumberColor Location Fig.
C204 RD Left Side of
Instrument
Panel6, 8, 9
C205 GY Left Side of
Instrument
Panel6, 8,
14
C301 RD Right C-Pillar 11
C302 BK Inner Left
Rear Quarter
Panel11
C303 BL/BK Left B-Pillar at
Rear Door10, 16
C304 BL/BK Right B-Pillar
at Rear Door12, 16
C305 NAT Left Side of
Instrument
Panel6, 8,
10
C306 BK Front Center
of Headliner9
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf11
Center High
Mounted Stop
LampBK Rear of Lamp 17
Center Stack
LampBK Center of
Instrument
Panel7
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel7
Clockspring GN Rear of
Steering
Wheel6
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal2
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower2
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK At Left Kick
Panel Area2Connector
Name/NumberColor Location Fig.
Decklid
SolenoidBK On Decklid 17
Dome Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Dome
Lamp/Intrusion
Sensor
(Built-Up-
Export)NAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door14
Driver Door
Lock MotorBK At Drivers
Door14
Driver Door
Lock SwitchBK At Drivers
Door14
Driver Power
MirrorGY At Drivers
Door14
Driver Power
Window MotorBK At Drivers
Door14
Driver Power
Window
Switch - C1BK At Drivers
Door14
Driver Power
Window
Switch - C2GY At Drivers
Door14
Engine
Coolant
Temperature
SensorBK Right Front of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine5
Fuel Injector
NO.1BK At Injector 4
Fuel Injector
NO. 2BK At Injector 4
Fuel Injector
NO. 3BK At injector 4
Fuel Injector
NO. 4BK At Injector 4
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
C303 BL/BK Left B-Pillar at
Left Rear
Door28, 35
C304 BL/BK Right B-Pillar
at Right Rear
Door29, 31,
35
C305 NAT Right Side of
Instrument
Panel25, 26,
29
C306 BK Front Center
of Headliner27
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf30
Center High
Mounted Stop
LampBK Rear of Lamp 36
Center Stack
LampBK Center of
Instrument
Panel24
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel24
Clockspring GN Rear of
Steering
Wheel25
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal23
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower19
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK Right Front
Kick Panel23
Decklid
SolenoidBK On Decklid 36
Dome
Lamp/Intrusion
SensorNAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door34
Driver Door
Lock MotorBK At Drivers
Door34Connector
Name/NumberColor Location Fig.
Driver Door
Lock SwitchBK At Drivers
Door34
Driver Power
MirrorBL At Drivers
Door34
Driver Power
Window MotorBK At Drivers
Door34
Driver Power
Window
Switch - C1BK At Drivers
Door34
Driver Power
Window
Switch - C2GY At Drivers
Door34
Engine
Coolant
Temperature
SensorBK Right Side of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine22
Fuel Injector
NO. 1BK At Injector 21
Fuel Injector
NO. 2BK At Injector 21
Fuel Injector
NO. 3BK At injector 21
Fuel Injector
NO. 4BK At Injector 21
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment20
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel24, 26
8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean all debris/rust from inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with MopartStud and Bearing Mount Adhesive.
Make certain the new plug is cleaned of all oil or
grease. Using a proper driver, drive plug into hole so
that the sharp edge of the plug is at least 0.5 mm
(0.020 inch.) inside the lead in chamfer (Fig. 3).
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to it's
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-ing to these standards, refer to Engine Diagnosis in
this section. The following procedures can assist in
achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system. Refer to
Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
Fig. 2 Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
Fig. 3 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
PLENGINE 9 - 3
GENERAL INFORMATION (Continued)

will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Inspect cyl-
inder walls after each 20 strokes, using a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 4).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.MEASURING WITH PLASTIGAGE
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings can
only be determined by removing the weight of the
crankshaft. This can be accomplished by either of
two methods:
PREFERRED METHOD
Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
ENGINE WITH 5 MAIN BEARINGS
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & 3
main bearing.
²When checking #3 main bearing shim #2 & 4
main bearing.
²When checking #4 main bearing shim #3 & 5
main bearing.
²When checking #5 main bearing shim #4 main
bearing.
ENGINE WITH 4 MAIN BEARING
²When checking #1 main bearing shim # 2 main
bearing.
Fig. 4 Cylinder Bore Cross-Hatch Pattern
1 ± CROSS-HATCH PATTERN
Fig. 5 Plastigage Placed in Lower Shell
1 ± PLASTIGAGE
9 - 4 ENGINEPL
GENERAL INFORMATION (Continued)