torque DODGE NEON 2000 Service Repair Manual

(9) Do not connect the battery negative cable.
Refer to Diagnosis and Testing for Airbag System
Test procedures.
DRIVER AIRBAG MODULE
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (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 ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
REMOVAL
When removing a deployed module, rubber gloves,
eye protection and long sleeved shirt should be worn,
as there may be deposits on the surface which could
irritate the skin and eyes.
(1) Disconnect and isolate the battery negative
cable (Fig. 4).
(2) Remove speed control switches or covers from
steering wheel armature and disconnect the wires
(Fig. 8).
(3) Remove two bolts attaching Driver Airbag Mod-
ule from the sides of steering wheel.(4) Lift module and disconnect airbag squib wire
connector and horn wire.
(5) Remove Driver Airbag Module from vehicle.
NOTE: When replacing a deployed driver airbag
module, the clockspring must also be replaced.
Refer to Clockspring Removal and Installation in
this section.
INSTALLATION
For installation, reverse the above procedures.
(1) Connect the squib wire to the module. Make
airbag connection by pressing straight in on the con-
nector. The connector should be fully seated. Feel for
positive snap to assure positive connection.
(2) Connect the horn wire.
(3) Install two bolts and tighten to 10 to 11 N´m
(90 to 100 in. lbs.) torque.
(4) Install covers to the steering wheel armature
or connect the wire connectors to the speed control
switches and install switches. Tighten fastener to 2
N´m (20 in. lbs.) torque.
(5) Do not connect battery negative cable. Refer to
Diagnosis and Testing for Airbag System Test proce-
dures.
Fig. 8 Driver Airbag Module Remove/Install
8M - 6 PASSIVE RESTRAINT SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the three module
retaining nuts to 22 to 34 N´m (200 to 300 in. lbs.)
torque. Do not connect battery negative cable. Refer
to Diagnosis and Testing for Airbag System Test pro-
cedures.
DEPLOYED MODULE
REMOVAL
When removing a deployed module, rubber gloves,
eye protection, and a long-sleeved shirt should be
worn, as there may be deposits on the surface which
could irritate the skin and eyes.
(1) Roll/fold airbag towards instrument panel.
(2) Close door over folded airbag and tape door
closed.
(3) Disconnect and isolate the battery negative
cable (Fig. 4).
(4) Remove instrument panel top cover. Refer to
Group 8E Instrument Panel Systems, Instrument
Panel Top Cover Removal and Installation.
(5) Remove three screws to glove box door and
remove door from instrument panel.
(6) Remove three passenger airbag cover screws
attaching cover to top of instrument panel (Fig. 9).
(7) Remove two passenger airbag cover screws
attaching cover to front lower instrument panel.
(8) Remove three module attaching nuts from the
support structure.
(9) Lift module up until the wire connector is visi-
ble and disconnect the 4-way wire connector from
module. Unlock the red locking tab and compress
lock to release the connector (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the module nuts to
22 to 34 N´m (200 to 300 in. lbs.) torque. Do not con-
nect battery negative cable. Refer to Diagnosis and
Testing for Airbag System Test procedures.
STEERING WHEEL
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (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 ACCI-DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
REMOVAL
(1) Adjust the steering wheel so that the tires are
in the straight ahead position. Then:
(a) Rotate the steering wheel half turn (180
degrees) to the right (clockwise).
(b) Lock column with the ignition cylinder lock.
(2) Disconnect and isolate the battery negative
cable (Fig. 4).
(3) Remove the speed control switches and discon-
nect the wire connectors or covers (Fig. 11).
(4) Remove the Driver Airbag Module attaching
bolts from the back of steering wheel.
(5) Lift module and disconnect the airbag and horn
wire connectors.
(6) Remove steering wheel retaining nut.
(7) Remove the steering wheel with a steering
wheel puller (Fig. 12). While removing the steering
wheel take care to feed the wires gently through the
holes in the steering wheel.
INSTALLATION
(1) Confirm that:
(a) The steering wheel position is a half turn
(180 degrees) to the right (clockwise).
(b) The column is locked with the ignition cylin-
der lock.
(c) Check that the turn signal stalk is in the
neutral position.
(2) Install the steering wheel ensuring the flats on
hub align with the clockspring. Pull the horn lead,
airbag and speed control leads through the larger
Fig. 11 Steering Wheel Remove/Install
8M - 8 PASSIVE RESTRAINT SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

slot. Ensure leads do not get pinched under the steer-
ing wheel.
(3) Install the steering wheel retaining nut, and
tighten it to 61 N´m (45 ft. lbs.) torque.
(4) Install the driver airbag module. Refer to
Driver Airbag Module Removal and Installation in
this section.
(5) Do not connect the battery negative cable.
Refer to Diagnosis and Testing for Airbag System
Test procedures.
ADJUSTMENTS
CLOCKSPRING CENTERING PROCEDURE
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE BEFORE
BEGINNING ANY AIRBAG SYSTEM COMPONENTREMOVAL OR INSTALLATION PROCEDURE. THIS
WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO
DISCONNECT BATTERY COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
If the rotating tape within the clockspring is not
positioned properly with the steering wheel and the
front wheels, the clockspring may fail during use.
The following procedureMUST BE USEDto center
the clockspring if:
²The clockspring is not known to be properly
positioned.
²The front wheels were moved.
²The steering wheel was moved from the half
turn (180 degrees) to the right (clockwise) position.
(1) Remove clockspring. Refer to Clockspring
Removal and Installation in this section.
(2) Rotate the clockspring rotor in the CLOCK-
WISE DIRECTION to the end of travel. Do not apply
excessive torque.
(3) From the end of travel, rotate the rotor three
full turns in the counterclockwise direction. The horn
wire and the squib wire should end up at the bottom.
If not, rotate the rotor counter clockwise until the
wires are properly orientated, but not more than half
turn (180 degrees). Engage clockspring locking mech-
anism.
(4) For installation, refer to Clockspring Removal
and Installation in this section.
(5) Do not connect battery negative cable. Refer to
Diagnosis and Testing for Airbag System Test
procedures.
Fig. 12 Steering Wheel Puller Installed
1 ± STEERING WHEEL
2 ± STEERING WHEEL PULLER
PLPASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 4).
(2) Disconnect each of the engine compartment
wire harness connectors. Refer to8W-90 - Connec-
tor Locationsin Group 8W - Wiring Diagrams for
more information on the locations of the affected con-
nectors.
(3) Remove the fasteners that secure each of the
engine compartment wire harness ground eyelets to
the vehicle body and chassis components. Refer to
8W-90 - Connector Locationsin Group 8W - Wir-
ing Diagrams for more information on the ground
eyelet locations.
(4) Disengage each of the retainers that secure the
engine compartment wire harness to the vehicle body
and chassis components. Refer to8W-90 - Connec-tor Locationsin Group 8W - Wiring Diagrams for
more information on the retainer locations.
(5) Remove the one screw and disengage the PDC
housing from the left inner fender well.
(6) Remove the PDC and the engine compartment
wire harness from the engine compartment as a unit.
INSTALLATION
NOTE: If the power distribution center (PDC) is
being replaced with a new unit, be certain to trans-
fer each of the fuses and relays from the old power
distribution center to the proper cavities of the new
power distribution center. Refer to Power Distribu-
tion in Group 8W - Wiring Diagrams for the proper
power distribution center cavity assignments.
(1) Position the PDC in the engine compartment.
(2) Align the PDC mounting pin with the inner
fender well hole.
(3) Place PDC down in engine compartment and
install retaining screw.
(4) Route the engine compartment wire harness
from the PDC through the engine compartment,
engaging each of the harness retainers to the mount-
ing provisions in the vehicle body and chassis compo-
nents. Refer to8W-90 - Connector Locationsin
Group 8W - Wiring Diagrams for more information
on the harness routing and retainer locations.
(5) Install and tighten the fasteners that secure
each of the engine compartment wire harness ground
eyelets to the vehicle body and chassis components.
Refer to8W-90 - Connector Locationsin Group
8W - Wiring Diagrams for more information on the
ground eyelet locations.
(6) Reconnect each of the engine compartment
wire harness connectors. Refer to8W-90 - Connec-
tor Locationsin Group 8W - Wiring Diagrams for
more information on the locations of the affected con-
nectors.
(7) Torque nut retaining positive battery cable at
PDC to 96 - 141 Nzm (85 - 130 in. lbs.).
(8) Reconnect the battery negative cable.
Fig. 4 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
PLPOWER DISTRIBUTION SYSTEMS 8O - 3
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position the mirror and install the (3) power
fold-away mirror retaining nuts (Fig. 9). Torque the
nuts to 20 N´m (177 in. lbs.).(2) Connect the power fold-away mirror electrical
connector and secure wire harness pushpin (Fig. 9).
(3) Verify mirror operation.
(4) Install the front door trim panel. Refer to
Group 23, BODY for the procedure.
(5) Connect the negative battery cable.
Fig. 9 Power Fold-Away Mirror Mounting - Right
Side
1 ± POWER MIRROR RETAINING NUTS
2 ± RIGHT FRONT DOOR
3 ± POWER MIRROR ELECTRICAL CONNECTOR
4 ± WIRE HARNESS PUSHPIN
8T - 4 POWER MIRRORSPL
REMOVAL AND INSTALLATION (Continued)

Component Page
Sunroof Switch.......................8W-64
Sunroof Vent Switch...................8W-64
Tail/Stop Lamps......................8W-51
Tail/Stop/Turn Signal Lamps..........8W-51, 52
Throttle Position Sensor................8W-30
Torque Converter Clutch Solenoid.........8W-30
Traction Control Switch.................8W-35
Trunk Key Cylinder Switch..............8W-61
Turn Signal Lamps....................8W-52
Underhood Lamp......................8W-44Component Page
Vehicle Speed Control Servo.............8W-33
Vehicle Speed Control Switch............8W-33
Vehicle Speed Sensor...................8W-30
Visor/Vanity Lamps....................8W-44
Wheel Speed Sensors...................8W-35
Windshield Washer Pump...............8W-53
Wipe/Wash Switch.....................8W-53
Wiper Motor.........................8W-53
8W - 02 - 2 8W - 02 COMPONENT INDEXPL

8W-11 FUSE BLOCK
Component Page
A/C Compressor Clutch Relay.......8W-11-11, 12
A/C Cycling Switch.................8W-11-7, 8
A/C Heater Blower Motor............8W-11-7, 8
Airbag Control Module.........8W-11-7, 8, 11, 12
Back-Up Lamp Switch..............8W-11-7, 8
Brake Shift Interlock Solenoid........8W-11-7, 8
Circuit Breaker No. 1 (FB)............8W-11-17
Circuit Breaker No. 2 (FB)............8W-11-18
Combination Flasher.................8W-11-6
Controller Anti-Lock Brake.........8W-11-11, 12
Driver Door Lock Switch...............8W-11-9
Driver Power Mirror.................8W-11-16
Driver Power Window Switch........8W-11-9, 17
Fuel Pump Relay.................8W-11-11, 12
Fuse 1 (FB).........................8W-11-6
Fuse 2 (FB).........................8W-11-6
Fuse 3 (FB).........................8W-11-6
Fuse 4 (FB).........................8W-11-6
Fuse 5 (FB).........................8W-11-7
Fuse 6 (FB).......................8W-11-7, 8
Fuse 7 (FB).......................8W-11-7, 8
Fuse 8 (FB).........................8W-11-8
Fuse 9 (FB)........................8W-11-11
Fuse 10 (FB)....................8W-11-10, 11
Fuse 10 (PDC)......................8W-11-16
Fuse 11 (FB)....................8W-11-10, 12
Fuse 12 (FB).......................8W-11-12
Fuse 14 (FB)....................8W-11-13, 14
Fuse 15 (FB)....................8W-11-13, 14
Fuse 16 (FB)....................8W-11-13, 14
Fuse 17 (FB)....................8W-11-19, 20
Fuse 18 (FB)....................8W-11-19, 20
Fuse 19 (FB).......................8W-11-19
Fuse 20 (FB).......................8W-11-16
Fuse Block............8W-11-2, 3, 6, 7, 8, 10, 11,
13, 14, 16, 17, 18, 19
Headlamp Leveling Switch............8W-11-20
Headlamp Switch...................8W-11-13
Instrument Cluster.....8W-11-10, 13, 14, 18, 19, 21
Leak Detection Pump................8W-11-11Component Page
Left City Lamp.....................8W-11-15
Left Front Fog Lamp.................8W-11-19
Left Front Side Marker Lamp..........8W-11-15
Left Headlamp................8W-11-19, 20, 21
Left Headlamp Leveling Motor.........8W-11-20
Left License Lamp..................8W-11-14
Left Park/Turn Signal Lamp...........8W-11-15
Left Tail/Stop Lamp.................8W-11-14
Left Tail/Stop/Turn Signal Lamp........8W-11-13
License Lamp......................8W-11-13
Multi- Function Switch.....8W-11-6, 13, 14, 18, 19
Park/Neutral Position Switch.........8W-11-7, 8
Passenger Door Lock Switch............8W-11-9
Passenger Power Mirror..............8W-11-16
Passenger Power Window Switch.....8W-11-9, 17
Power Distribution Center............8W-11-16
Power Mirror Switch................8W-11-6, 9
Powertrain Control Module.........8W-11-11, 12
Radiator Fan Relay...............8W-11-11, 12
Radio........................8W-11-6, 13, 14
Rear Window Defogger...............8W-11-16
Rear Window Defogger Switch......8W-11-7, 8, 16
Remote Keyless Entry Module......8W-11-10, 13,
14, 18
Right City Lamp....................8W-11-15
Right Front Fog Lamp...............8W-11-19
Right Front Side Marker Lamp.........8W-11-15
Right Headlamp...............8W-11-19, 20, 21
Right Headlamp Leveling Motor........8W-11-20
Right License Lamp.................8W-11-14
Right Park/Turn Signal Lamp..........8W-11-15
Right Tail/Stop Lamp................8W-11-14
Right Tail/Stop/Turn Signal Lamp.......8W-11-13
Sentry Key Immobilizer Module........8W-11-10
Sunroof Control Module...............8W-11-6
Sunroof Switch......................8W-11-6
Torque Converter Clutch Solenoid....8W-11-11, 12
Wipe/Wash Switch...................8W-11-6
Wiper Motor........................8W-11-6
PL8W - 11 FUSE BLOCK 8W - 11 - 1

9FUSE10A
29
BLOCK
FUSE9
ST-RUN A21
10
30
15A
FUSE
10
F12
18
DB/WTF12
18
DB/WTF15
18
DG/WT
14
C30517C10411 C11 A17
2
UP-EXPORT) (EXCEPT BUILT-
PUMP
DETECTION
LEAK
AIRBAG
CONTROL
MODULE
F12
18
DB/WTF12
18
DB/WT
3
C120
4
59
63
33
29
69
70
2C1021C108
F12
18
DB/WTF12
18
DB/WTF12
18
DB/WTF12
18
DB/WTF12
18
DB/WTF12
18
DB/WT
CONTROLLER
ANTI-LOCK
BRAKE
FUEL
PUMP
RELAY RADIATOR
FAN
RELAY
POWERTRAIN
CONTROL
MODULERELAY CLUTCH
COMPRESSOR
A/C
(ATX) SOLENOID
CLUTCH
CONVERTER
TORQUES109
F12
18
DB/WTF12
18
DB/WT
(IN PDC)
(IN PDC)(IN PDC)
(8W-11-2)
(8W-11-3) (8W-10-10)
(8W-30-9)(8W-43-2)
(8W-35-3)
(8W-30-10) (8W-42-5)
(8W-30-9)(8W-42-2) (8W-30-9)
PL8W-11 FUSE BLOCK
LHD8W - 11 - 11
PLI01111008W-10

11FUSE15A 10A
FUSE
12
3132
BLOCK FUSE
1112
ST-RUN A21
F15
18
DG/WT
14
AIRBAG
CONTROL
MODULE
11C104C11F12
18
DB/WT
F12
18
DB/WT
TORQUE
CONVERTER
CLUTCH
SOLENOID
(ATX)A/C
COMPRESSOR
CLUTCH
RELAY
MODULE CONTROL
POWERTRAINRELAY FAN
RADIATOR
RELAY PUMP
FUELBRAKE ANTI-LOCK
CONTROLLER
DB/WT18 F12DB/WT18 F12DB/WT18 F12DB/WT18 F12DB/WT18 F12DB/WT18 F12
C1081C1022
70
69
29
33
63
59
4
20C1
3
F12
18
DB/WTF12
18
DB/WT
S109
(IN PDC)
(IN PDC) (IN PDC)
(8W-11-2)
(8W-11-3) (8W-10-10)
(8W-43-2)
(8W-30-9) (8W-42-2)
(8W-30-9)(8W-42-5)
(8W-30-10)(8W-35-3)
8W - 11 - 12 8W-11 FUSE BLOCK
RHDPL
008W-10PLI01112

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay...........8W-30-9
A/C High Pressure Switch.............8W-30-11
Airbag Control Module................8W-30-4
Automatic Shut Down Relay........8W-30-2, 3, 5
Brake Lamp Switch............8W-30-12, 13, 14
Brake Shift Interlock Solenoid.........8W-30-13
Brake Warning Indicator Switch........8W-30-13
Camshaft Position Sensor..............8W-30-7
Center High Mounted Stop Lamp.......8W-30-14
Clockspring........................8W-30-12
Clutch Interlock Switch..............8W-30-15
Controller Anti-Lock Brake..........8W-30-4, 13
Crankshaft Position Sensor............8W-30-7
Data Link Connector................8W-30-2, 4
Engine Coolant Temperature Sensor.....8W-30-7
Engine Oil Pressure Switch............8W-30-2
Engine Starter Motor Relay...........8W-30-15
Fuel Injector No. 1...................8W-30-5
Fuel Injector No. 2...................8W-30-5
Fuel Injector No. 3...................8W-30-5
Fuel Injector No. 4...................8W-30-5
Fuel Pump Module..................8W-30-10
Fuel Pump Relay...................8W-30-10
Fuel Tank.........................8W-30-10
Fuse 6 (FB)........................8W-30-13
Fuse 7 (FB)........................8W-30-13
Fuse 10 (FB).....................8W-30-9, 10
Fuse 11 (FB).....................8W-30-9, 10
Fuse 21 (PDC)..................8W-30-2, 4, 10
Fuse 23 (PDC)......................8W-30-13
Fuse Block....................8W-30-9, 10, 13
G101........................8W-30-3, 12, 15Component Page
G102.......................8W-30-2, 4, 13, 15
G201.............................8W-30-12
G303.............................8W-30-10
Generator.........................8W-30-11
Idle Air Control Motor................8W-30-8
Ignition Coil........................8W-30-5
Inlet Air Temperature Sensor...........8W-30-6
Instrument Cluster................8W-30-4, 10
Knock Sensor.......................8W-30-6
Leak Detection Pump.................8W-30-9
Left Tail/Stop Lamp.................8W-30-14
Manifold Absolute Pressure Sensor......8W-30-6
Multi-Function Switch...............8W-30-14
Noise Suppressor....................8W-30-5
Oxygen Sensor 1/1 Upstream...........8W-30-3
Oxygen Sensor 1/2 Downstream.........8W-30-3
Park/Neutral Position Switch..........8W-30-15
Power Distribution Center......8W-30-2, 4, 10, 13
Power Steering Pressure Switch........8W-30-15
Powertrain Control Module.....8W-30-2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, 13, 15
Proportional Evap/Purge Solenoid.......8W-30-15
Radiator Fan Relay...................8W-30-9
Remote Keyless Entry Module..........8W-30-4
Right Tail/Stop Lamp................8W-30-14
Sentry Key Immobilizer Module.........8W-30-4
Throttle Position Sensor...............8W-30-6
Torque Converter Clutch Solenoid.......8W-30-9
Vehicle Speed Control Servo........8W-30-12, 13
Vehicle Speed Control Switch..........8W-30-12
Vehicle Speed Sensor.................8W-30-8
PL8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1