service DODGE NEON 2000 Service Repair Manual

On most vehicles another resistor has been added
to the at rest circuit causing the PCM to never see 5
volts. This was done for diagnostic purposes. If the
switch circuit should open (bad connection) then the
PCM will see the 5 volts and know the circuit is bad.
The PCM will then set an open circuit fault.
STOP LAMP SWITCH
DESCRIPTION
The switch is mounted on the brake pedal mount-
ing bracket under the instrument panel.
OPERATION
Vehicles equipped with the speed control option use
a dual function stop lamp switch. The PCM monitors
the state of the dual function stop lamp switch. Refer
to the Brake section for more information on stop
lamp switch service and adjustment procedures.
The brake switch is equipped with three sets of
contacts, one normally open and the other two nor-
mally closed (brakes disengaged). The PCM sends a
12 volt signal to one of the normally closed contacts
in the brake switch, which is connected to a ground.
With the contacts closed, the 12 volt signal is pulled
to ground causing the signal to go low. The low volt-
age signal, monitored by the PCM, indicates that the
brakes are not applied. When the brakes are applied,
the contacts open, causing the PCM's output voltage
to go high, disengaging the speed control also
grounding the dump solenoid.
The second set of normally closed contacts is sup-
plied battery voltage any time speed control is
selected. From the brake switch, current is routed to
the speed control servo solenoids. The speed control
solenoids (vacuum, vent and dump) are provided this
current any time the speed control is ON and the
brakes are disengaged. When the driver applies the
brakes, the contacts open and current is interrupted
to the solenoids. The normally open contacts are fed
battery voltage. When the brakes are applied, battery
voltage is supplied to the stop lamps.
SERVO CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
VACUUM RESERVOIR
OPERATION
The reservoir stores engine vacuum in the reser-
voir. When engine vacuum drops, as in climbing a
grade while driving, the reservoir supplies the vac-
uum needed to maintain proper speed control opera-
tion. The vacuum reservoir cannot be repaired and
must be replaced if faulty.
VEHICLE SPEED SENSOR
The Vehicle Speed Sensor (VSS) is a pulse genera-
tor mounted to an adapter near the transmission out-
put shaft. The sensor is driven through the adapter
by a speedometer pinion gear. The VSS pulse signal
to the speedometer/odometer is monitored by the
PCM speed control circuitry to determine vehicle
speed and to maintain speed control set speed.
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
REMOVAL
(1) Disconnect electrical connector from servo (Fig.
2).
(2) Disconnect vacuum hose from servo
(3) Remove 2 nuts retaining cable to servo.
(4) Remove retaining clip pin holding cable to
servo.
Fig. 2 Speed Control Servo
PLVEHICLE SPEED CONTROL SYSTEM 8H - 3
DESCRIPTION AND OPERATION (Continued)

REMOVAL AND INSTALLATION
COMBINATION FLASHER
The flasher is mounted to the back side of the
multi-function switch (Fig. 2). To gain access the
upper steering column shroud must be removed.
Refer to Group 8E Instrument Panel Systems, Steer-
ing Column Shroud Removal and Installation. The
flasher can be removed by pulling it toward the
instrument cluster (forward). The flasher is serviced
separately from the multi-function switch.
MULTI-FUNCTION SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Remove both upper and lower steering column
shrouds. Refer to Group 8E Instrument Panel Sys-
tems, Steering Column Shroud Removal and Instal-
lation.
Fig. 3 Combination Flasher Connector (A)
Fig. 4 Multi-Function Switch Connector (B)
Fig. 5 Windshield Wiper/Washer Switch Connector
(C)
Fig. 6 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
PLTURN SIGNAL and HAZARD WARNING SYSTEMS 8J - 5
DIAGNOSIS AND TESTING (Continued)

WINDSHIELD WIPER MODULE
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 7).
(2) Remove wiper arms and blades. Refer to Wind-
shield Wiper Arm Removal and Installation in this
section.
(3) Remove the left side cowl cover. Refer to Group
23 Body, Cowl Cover Removal and Installation.
(4) Disconnect motor posi-lock harness connector.
(5) Remove windshield wiper module mounting
screws and remove module from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Tighten the mounting screws to 7 to 9 N´m (60 to 80
in. lbs.) torque.
WINDSHIELD WIPER MOTOR
REMOVAL
(1) Remove windshield wiper module. Refer to
Windshield Wiper Module Removal and Installation
in this section.(2) Remove linkage from motor crank. Insert
screwdriver or equivalent between crank and linkage
then twist and lift straight up on linkage.
(3) Remove three motor mounting screws and sep-
arate motor from linkage.
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.
WINDSHIELD WIPER/WASHER SWITCH
To service the wiper switch, refer to Group 8J Turn
Signal and Hazard Warning Systems, Multi-Function
Switch Removal and Installation.
CLEANING AND INSPECTION
WINDSHIELD WIPER BLADE(S)
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
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
Adjustments, Wiper Arm Adjustment in this section.
ADJUSTMENTS
WINDSHIELD WIPER ARM(S)
(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. 9).
(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 slightly
above the park line. Make sure that the wipers are
in the PARK position.
Fig. 7 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
8K - 6 WINDSHIELD WIPER and WASHER SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

WINDSHIELD WASHER SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WINDSHIELD WASHER NOZZLE(S)............8
WINDSHIELD WASHER SYSTEM.............8
DIAGNOSIS AND TESTING
WINDSHIELD WASHER SYSTEM.............9REMOVAL AND INSTALLATION
WINDSHIELD WASHER HOSE................9
WINDSHIELD WASHER NOZZLES.............9
WINDSHIELD WASHER RESERVOIR..........10
WINDSHIELD WASHER PUMP...............10
DESCRIPTION AND OPERATION
WINDSHIELD WASHER NOZZLE(S)
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 identical.
WINDSHIELD WASHER SYSTEM
All models are equipped with electrically 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.
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 - Typical
1 ± HOOD
2 ± ADJUST WITH A PIN
3 ± NOZZLE
4 ± FWD
Fig. 2 Windshield Washer Pattern - Typical
1 ± NOZZLE AIR TARGET
Fig. 3 Windshield Washer Reservoir
1 ± WINDSHIELD WASHER PUMP
2 ± SPEED CONTROL VACUUM RESERVOIR
3 ± WINDSHIELD WASHER HOSE
8K - 8 WINDSHIELD WIPER and WASHER SYSTEMSPL

LAMPS
TABLE OF CONTENTS
page page
LAMP DIAGNOSIS......................... 1
HEADLAMP ALIGNMENT.................... 4
LAMP BULB SERVICE...................... 7LAMP SERVICE........................... 12
LAMP SYSTEMS.......................... 16
BULB APPLICATION....................... 17
LAMP DIAGNOSIS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
DIAGNOSTIC PROCEDURES................1
SAFETY PRECAUTIONS....................1
DAYTIME RUNNING LAMP MODULE...........1DIAGNOSIS AND TESTING
HEADLAMP DIAGNOSIS....................1
FOG LAMP..............................3
DESCRIPTION AND OPERATION
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to Group 8W,
Wiring Diagrams for component locations and circuit
information.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
DAYTIME RUNNING LAMP MODULE
PL vehicles built for use in Canada are equipped
with a Daytime Running Lamp (DRL) system. Turn
signal lamp circuitry always comes from the multi-
function switch, and goes to the cluster connector,
into the cluster, then back out to the front turn sig-
nal switch lamps. The Canadian cluster provides
steady illumination of the front turn signal when the
ignition switch is in the ON position. The DRL func-
tion may be inhibited by activating the turn signals,
the hazard flashers, the headlamp switch, or park
brake.
DIAGNOSIS AND TESTING
HEADLAMP DIAGNOSIS
Always begin any diagnosis by testing all of the
fuses and circuit breakers in the system. Refer to
Group 8W, Wiring Diagrams.
Conventional and halogen headlamps are inter-
changeable. It is recommended that they not be
intermixed on a given vehicle.
PLLAMPS 8L - 1

HEADLAMP ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT....................4
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION........4ADJUSTMENTS
HEADLAMP ADJUSTMENT USING
ALIGNMENT SCREEN....................4
FOG LAMP ALIGNMENT....................6
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT
Headlamps and Fog Lamps should be aligned
using the screen method which is provided in this
section.The preferred headlamp alignment set-
ting is 0 for the left/right adjustment and 0 for
the up/down adjustment.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens.
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall
(Fig. 1).(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) A small dot is molded into each headlamp lens
signifying the center of the headlamp. Measure the
distance from the center of the headlamp to the floor.
Transfer measurement to the alignment screen (with
tape). Use this line for up/down adjustment refer-
ence.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
The PL headlamp low beam pattern has a distinct
horizontal cutoff line which is used to visually align
the headlamps. A properly aimed headlamp will have
the horizontal cutoff line of the low beam pattern
centered on the low beam pattern centered on the
horizontal center of headlamp line. The side to side
left edge of the low beam hot spot should be located
75 mm (3 inches) to the left of the headlamp center
line (Fig. 1). The high beams on a vehicle with aero
headlamps cannot be aligned. The high beam pattern
should be correct when the low beams are aligned
properly.
To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern.
8L - 4 LAMPSPL

LAMP BULB SERVICE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BULB...................................7
REMOVAL AND INSTALLATION
HEADLAMP BULB.........................7
FOG LAMP BULB..........................8
PARK AND TURN SIGNAL LAMP BULB.........8
FRONT SIDE MARKER LAMP BULB...........9
CENTER HIGH MOUNTED STOP LAMP BULB....9
TAIL, STOP, BACK-UP AND TURN SIGNAL
LAMP BULB............................9LICENSE PLATE LAMP BULB...............10
UNDERHOOD LAMP BULB.................10
REAR CARGO LAMP BULB.................10
DOME LAMP BULB.......................10
TRANSAXLE RANGE INDICATOR LAMP BULB . . 10
GLOVE BOX LAMP BULB...................11
FLOOR CONSOLE LAMP BULB..............11
VISOR VANITY LAMP BULB.................11
DESCRIPTION AND OPERATION
BULB
The electric light bulb is a source of electromag-
netic radiation which generates light. Vehicles use
many different types of bulbs:
²Headlamp bulb
²Fog Lamp bulb
²Tail Lamp bulb
²Stop Lamp bulb
²Turn Signal bulb
²Back up Lamp bulb
²Dome Lamp bulb
²Transaxle Range Indicator Lamp bulb (PRNDL)
²Glove Box Lamp bulb
²Floor Console Lamp bulb
²Rear Cargo Lamp bulb
²Visor Vanity Lamp bulb
²Underhood Lamp bulb
²etc.
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Remove screws attaching headlamp module to
upper crossmember.
(3) Remove headlamp module from vehicle.
(4) Disconnect wire connector from back of head-
lamp bulb.
(5) Rotate retaining ring counterclockwise one
quarter turn.
(6) Remove retaining ring from headlamp module.
(7) Remove bulb from headlamp module (Fig. 1).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Install bulb into headlamp module.
(2) Install retaining ring to headlamp module.
(3) Rotate retaining ring clockwise one quarter
turn.
(4) Connect wire connector to the back of head-
lamp bulb.
(5) Place headlamp module in position.
(6) Install screws attaching headlamp module to
upper crossmember.
(7) Close hood.
PLLAMPS 8L - 7

LAMP SERVICE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
LAMP ASSEMBLIES.......................12
REMOVAL AND INSTALLATION
HEADLAMP MODULE.....................12
FOG LAMP..............................13
PARK AND TURN SIGNAL LAMP BULB........13
FRONT SIDE MARKER LAMP...............13
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)..............................14TAIL, STOP AND TURN SIGNAL LAMP........14
LICENSE PLATE LAMP....................14
UNDERHOOD LAMP......................14
REAR CARGO LAMP......................15
DOME LAMP............................15
GLOVE BOX LAMP BULB..................15
FLOOR CONSOLE LAMP BULB..............15
VISOR VANITY LAMP......................15
DESCRIPTION AND OPERATION
LAMP ASSEMBLIES
The lamp assemblies or modules generally consist
of a housing, reflector(s) and lens that directs a light
source. Vehicles use many different types of lamps:
²Headlamp
²Fog Lamp
²Tail Lamp
²Stop Lamp
²Turn Signal Lamp
²Back up Lamp
²Dome Lamp
²Transaxle Range Indicator Lamp (PRNDL)
²Glove Box Lamp
²Floor Console Lamp
²Rear Cargo Lamp
²Visor Vanity Lamp
²Underhood Lamp
²etc.
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
(1) Release hood latch and open hood.
(2) Remove screws attaching headlamp module to
upper crossmember.
(3) Remove headlamp module from vehicle.
(4) Disconnect wire connectors from back of head-
lamp module.
(5) Remove headlamp module (Fig. 1).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Connect wire connectors to the back of head-
lamp module.
(2) Place headlamp module in position.
(3) Install screws attaching headlamp module to
upper crossmember.
(4) Close hood.
8L - 12 LAMPSPL

BULB APPLICATION
TABLE OF CONTENTS
page page
SPECIFICATIONS
EXTERIOR LAMPS........................17INTERIOR LAMPS........................17
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the chart below.
Damage to lamp can result. Do not touch halogen
bulbs with fingers or other oily surfaces. Bulb life
will be reduced.
LAMP BULB
Back Up Lamp................3157 ± P27/7W
Center High Mounted Stop Lamp
(CHMSL).........................W16W
Front Fog Lamp..................... GE881
Front Park/Turn Signal Lamp..........3157NA
Front Side Marker Lamp................. 168
Headlamp............................9007
License Plate Lamp..................... 168
Rear Tail/Stop/
Turn Signal Lamp............3157 ± P27/7W
INTERIOR LAMPS
Service procedures for most of the lamps in the
instrument panel, Instrument cluster and switches
are located in Group 8E, Instrument Panel and
Gauges.
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the chart below.
Damage to lamp can result.LAMP BULB
ABS Indicator......................... LED
Airbag Indicator....................... LED
Brake System Warning Indicator.......... LED
Climate Controls....................... LED
Console Gear Selector W/Auto...........PC194
Dome Lamp..........................T579
Floor Console Lamp..................... T37
Front Fog Lamp Indicator................ LED
Glove Compartment....................T194
High Beam Lamp Indicator.............PC194
Ignition Lock........................... 161
Instrument Cluster Illumination.........PC194
Low Fuel Indicator..................... LED
Low Oil Pressure Indicator............... LED
Rear Cargo...........................T906
Seat Belt Indicator..................... LED
Security Alarm Indicator................. LED
Malfunction Indicator Light.............. LED
TRAC OFF Indicator.................... LED
Turn Signal Indicator..................PC194
Underhood............................ 105
Visor Vanity........................6501966
Voltage Indicator....................... LED
All the inside bulbs brass or glass wedge base. Alu-
minum base bulbs are not approved and should not
be used for replacement.
PLLAMPS 8L - 17

LAMPS
TABLE OF CONTENTS
page page
LAMP DIAGNOSIS......................... 1
HEADLAMP ALIGNMENT.................... 2
LAMP BULB SERVICE...................... 4LAMP SERVICE........................... 12
BULB APPLICATION....................... 19
LAMP DIAGNOSIS
TABLE OF CONTENTS
page
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR...............1
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR
This vehicle is equipped with a remote headlamp
leveling system. This system allows the driver to
adjust the vertical headlamp aim from the interior of
the vehicle to compensate for passenger or cargo
load. A headlamp leveling switch is located in the
instrument panel (Fig. 1) and controls the headlamp
leveling motor which is mounted to the rear of the
headlamp assembly.
Fig. 1 Headlamp Leveling Switch Position &
Orientation
1 ± HEAD LAMP LEVELING SWITCH
2 ± CENTER INSTRUMENT BEZEL
PLLAMPS 8L - 1