air conditioning DODGE NEON 2000 Service User Guide

GENERATOR BELT
REMOVAL
(1) Remove power steering pump/air conditioning
compressor drive belt.
(2) Loosen pivot bolt, then locking nut and adjust-
ing bolt (Fig. 36).
(3) Remove generator belt.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
INSTALLATION
(1) Install belt and/or adjust belt tension by tight-
ening adjusting bolt. Adjust belt to specification
shown in Belt Tension Chart.
NOTE: Due to space limitations, the use of a belt
tension gauge is limited. Therefore, measure the
belt deflection at the center span of the generator
belt. Refer to Belt Tension Chart for specifications.
(2) Tighten pivot bolt to 54 N´m (40 ft. lbs.) and
locking nut to 54 N´m (40 ft. lbs.) (Fig. 36).
Fig. 33 Accessory BeltÐRemoving
1 ± 17mm WRENCH
Fig. 34 Power Steering/Air Conditioning Belt
1 ± BELT
2 ± P/S PULLEY
3 ± TENSIONER PULLEY
4 ± CRANKSHAFT PULLEY
5 ± BELT6 ± P/S PULLEY
7 ± TENSIONER PULLEY
8 ± A/C PULLEY
9 ± CRANKSHAFT PULLEY
PLCOOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)

WIRING DIAGRAMS
TABLE OF CONTENTS
page page
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
ANTI-LOCK BRAKES.................. 8W-35-1
AUDIO SYSTEM..................... 8W-47-1
CHARGING SYSTEM.................. 8W-20-1
COMPONENT INDEX.................. 8W-02-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND LOCATIONS...... 8W-90-1
FRONT LIGHTING.................... 8W-50-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
FUSE BLOCK........................ 8W-11-1
GENERAL INFORMATION.............. 8W-01-1
GROUND DISTRIBUTION.............. 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
INSTRUMENT CLUSTER............... 8W-40-1INTERIOR LIGHTING.................. 8W-44-1
POWER DISTRIBUTION............... 8W-10-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SUNROOF................... 8W-64-1
POWER WINDOWS................... 8W-60-1
REAR LIGHTING..................... 8W-51-1
REAR WINDOW DEFOGGER............ 8W-48-1
SPLICE INFORMATION................ 8W-70-1
SPLICE LOCATIONS.................. 8W-95-1
STARTING SYSTEM.................. 8W-21-1
TURN SIGNALS...................... 8W-52-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
WIPERS............................ 8W-53-1
PLWIRING DIAGRAMS 8W - 1

8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Clutch................8W-42-2
A/C Compressor Clutch Relay...........8W-42-2
A/C Cycling Switch...............8W-42-3, 5, 6
A/C High Pressure Switch.............8W-42-5
A/C Low Pressure Switch............8W-42-5, 6
A/C Heater Blower Motor............8W-42-3, 4
A/C Heater Control...............8W-42-3, 4, 6
Blower Motor Resistor Block..........8W-42-3, 4
Diode No. 1.........................8W-42-2
Fuse 6 (FB).....................8W-42-3, 4, 6
Fuse 6 (PDC).......................8W-42-5
Fuse 7 (FB).....................8W-42-3, 4, 6
Fuse 10 (FB)......................8W-42-2, 5Component Page
Fuse 11 (FB)......................8W-42-2, 5
Fuse 15 (FB)......................8W-42-3, 4
Fuse 22 (PDC)......................8W-42-2
Fuse Block..................8W-42-2, 3, 4, 5, 6
G103............................8W-42-2, 5
G203............................8W-42-3, 4
Instrument Cluster.................8W-42-3, 4
Multi-Function Switch..............8W-42-3, 4
Power Distribution Center...........8W-42-2, 5
Powertrain Control Module...........8W-42-2, 5
Radiator Fan Motor..................8W-42-5
Radiator Fan Relay...................8W-42-5
PL8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1

22
29 31
3033
POWER
DISTRIBUTION
CENTER
15A
FUSE
10
10
30BLOCK FUSE
F12
18
DB/WT
F12
18
DB/WT
F12
18
DB/WT
Z1
20
BK
G103CLUTCH COMPRESSOR
A/C
C2
64
POWERTRAIN
CONTROL
MODULE S109
C28
18
DB/OR
A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
ST-RUN A21
20A
FUSE
22
1
2
DIODE
C3 20DB/BK
20BK Z1
DB/BK20 C3
NO. 1
11C104
Z1
12
BK
S119
31 11
11FUSE15A
LHD RHD
A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)
A17
20
RD/BK
C11
BATT A0
(8W-10-2)
(8W-10-3) (8W-11-11)(8W-11-2)
(8W-11-3)
(8W-15-7) (8W-30-9) (8W-11-11)
(8W-11-12)(8W-10-16) (8W-10-10)
(8W-15-5) (8W-11-12)
(8W-10-7)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATERPL
008W-10PLI04202

C4
14
TNC5
14
LGC6
14
LBC7
14
BK/TN
BLOCK RESISTOR
MOTOR
BLOWER
C2
22
DB/YL
C2
22
DB/YL1
C203
S204
6
26
20A
FUSE
6
BLOCK FUSE
C1
14
DG
C7
14
BK/TN 4
C203
6C203
1
2
5179
SWITCH
OUTPUT
MOTOR BLOWER
HEATER
A/C-
M
F33
20
PK/RD
13 HI-A/C 12 M2-A/C
11 M1-A/C
10 LOW-A/C
9 BLOWER-LOW
8 BLOWER-M1
7 BLOWER-M2
6 BLOWER-HI
5 DEF
4 DEF/FLOOR 1 PANEL 0 OFF
2 FLOOR/PANEL
3 FLOOR
ILLUMINATION
A/C-
HEATER
CONTROL
9
60
10
11
12
13
12
3
4
5MODE
SWITCH
SWITCH BLOWER
73 4 5
1
26
3MODE
15FUSE15A
35 15
RUN A22BATT A3
20
9
C2027698
C5
14
LG
SWITCH CYCLING
A/C
C4
14
TNC6
14
LBC7
14
BK/TN
12 14
CLUSTER INSTRUMENT
L7
20
BK/YL
E2
22
OR
S206
C7
14
BK/TNC7
14
BK/TN
Z8
14
BK/VTZ8
14
BK/VTS218
DG14C1
G203
HEADLAMP
SWITCH
OUTPUT
PANEL
LAMPS
DRIVER
S213
7FUSE20A
277
RHD LHD
8
7
MULTI-
FUNCTION
SWITCH
HEADLAMP
SWITCH
3
2 1 0
3 REAR FOG 2 HEAD
1 PARK
0 OFF
BUILT-UP-EXPORT
(8W-11-2)
(8W-11-3)
(8W-11-7) (8W-11-15)
(8W-11-16) (8W-10-9) (8W-10-9)
(8W-42-6)
(8W-40-9)
(8W-44-5)
(8W-15-10)
(8W-15-10)
(8W-11-15)
(8W-11-16) (8W-11-8)
(8W-50-6)
PL8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
PLI04203008W-10

C4
14
TNC5
14
LGC6
14
LBC7
14
BK/TN
BLOCK RESISTOR
MOTOR
BLOWER
S204
6
26
20A
FUSE
6
BLOCK FUSE
C1
14
DG
C7
14
BK/TN 4
C203
6C203
1
2
5179
MOTOR BLOWER
HEATER
A/C-
M
4 BLOWER-HI 1 BLOWER-LOW 0 OFF
2 BLOWER-M1
3 BLOWER-M2
ILLUMINATION
A/C-
HEATER
CONTROL
01
2
3
4
SWITCH BLOWER
3 4 5
1
2
15FUSE15A
35 15
RUN A22BATT A3
C2027698
C5
14
LGC4
14
TNC6
14
LBC7
14
BK/TN
C7
14
BK/TNC7
14
BK/TN
Z8
14
BK/VTZ8
14
BK/VTS218
DG14C1
G203
7FUSE20A
277
RHD LHD
0 OFF
1 PARK
2 HEAD
3 REAR FOG
0
123
SWITCH HEADLAMPSWITCH
FUNCTION
MULTI-
S213
DRIVERLAMPSPANEL OUTPUTSWITCH HEADLAMP
S206
OR22 E2
BK/YL20 L7
INSTRUMENT
CLUSTER
14
12
9 20
7PK/RD20 F33
BUILT-UP-EXPORT
(8W-11-2)
(8W-11-3)
(8W-11-7) (8W-11-15)
(8W-11-16) (8W-10-9) (8W-10-9)
(8W-15-10)
(8W-15-10)
(8W-11-8)
(8W-50-6)
(8W-11-15)
(8W-11-16)
(8W-44-5)(8W-40-9)
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER
HEATER ONLYPL
008W-10PLI04204

BATT A0
30A
FUSE
6
70
71
6973
6
1
2
M
G103
S119
Z1
12
BK
Z1
14
BK
POWER
DISTRIBUTION
CENTER
10
30
15A
FUSE
10
BLOCK FUSE
C10411
S109
(IN PDC) RELAY
FAN
RADIATOR
5538C2 C1
2
1
SWITCH PRESSURE
HIGH
A/C
1 2
A/C
LOW
PRESSURE
SWITCH
1
A/C
SWITCH
SENSESWITCH CYCLING
A/C
1C102
C1043
C2033
C20
18
BR/OR
C20
20
BR/OR
C22
20
DB/WT
C21
20
DB/OR
C21
22
DB/OR
C21
22
DB/OR
C27
18
DB/PK
F12
18
DB/WT
F12
18
DB/WT
F12
18
DB/WT
A16
14
GY
POWERTRAIN
CONTROL
MODULERADIATOR
FAN
RELAY
CONTROLA/C
SWITCH
SENSE
MOTOR FAN
RADIATOR
C11
C3 11FUSE
15A
31 11
RHD LHD
ST-RUN A21
LG12 C25(8W-10-7)
(8W-10-11)
(8W-15-7) (8W-15-5)(8W-10-2)
(8W-10-3)
(8W-11-11)(8W-11-2)
(8W-11-3)
(8W-11-11)
(8W-11-12)(8W-42-6)
(8W-30-9)
(8W-30-11) (8W-11-12) (8W-10-10)
PL8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
PLI04205008W-10

10A
FUSE
7 7
27
RUN A22
266
6FUSE
10A
FUSE
BLOCK
321
2
6
2C203
1C2033
C1043
MODE
SWITCH
OUTPUTA/C
SWITCH
SENSE
S216
OUTPUTSWITCHMODE
SENSE SWITCHA/C FUSED
IGNITION
SWITCH
OUTPUT
(RUN) LHD RHD
F20
20
WT
F20
20
WT
F20
22
WT
C2
22
DB/YL
C2
22
DB/YL
C21
22
DB/OR
C21
22
DB/OR
C21
20
DB/OR
A/C-
HEATER
CONTROL
SWITCH PRESSURE
LOW
A/CSWITCH CYCLING
A/C
C3 (8W-11-7)(8W-10-9)
(8W-11-8)(8W-11-2)
(8W-11-3)
(8W-11-7)
(8W-11-8)
(8W-42-3)
(8W-42-5)
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATERPL
008W-10PLI04206

NOTE: Engine mount must be installed in the orig-
inal position on body frame rail. If mount was not
marked or frame rail was replaced, perform the fol-
lowing procedure.
(2) Perform the following procedure if mount posi-
tion was not previously marked or the frame rail was
replaced:
a. Insert new mount loosely in frame rail.
b. Align the four holes in the mount with the mat-
ing holes in the rail such that the holes are concen-
tric (frame rail holes centered in the mount holes).
c. Using a permanent ink marker or equivalent,
mark the position of engine mount to the body frame
rail while maintaining mounting hole concentricity.
(3) Ensure the mount maintains originally marked
position and install mount bolts. Tighten bolts to 28
N´m (250 in. lbs.) (Fig. 19).
(4) Install engine mount bracket. Refer to proce-
dure in this section.
(5) Install bolt attaching right engine mount to
bracket and tighten to 118 N´m (87 ft. lbs.) (Fig. 18).
(6) Remove support from under engine.
(7) Install upper and lower engine torque struts.
Refer to procedure in this section.
(8) Install crankshaft damper. Refer to procedure
in this section.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
ENGINE MOUNT BRACKETÐRIGHT
REMOVAL
(1) Remove upper and lower torque struts. Refer to
procedure in this section.(2) Remove power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(3) Support engine with a suitable jack.
(4) Remove engine mount through bolt access plug
(Fig. 20)
(5) Remove right engine mount to bracket through
bolt (Fig. 21).
(6) Remove engine mount bracket attaching bolts
(Fig. 22).
(7) Bracket removal requires engine to be raised
slightly to obtain engine-to-body clearance.
INSTALLATION
(1) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 22).
(2) Install bolt attaching engine mount to bracket
(Fig. 21). Tighten bolt to 118 N´m (87 ft. lbs.).
(3) Install mount bolt access plug (Fig. 20).
(4) Remove support from under engine.
(5) Install power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(6) Install upper and lower torque struts. Refer to
procedure in this section.
Fig. 19 Engine MountÐRight
1 ± SNUBBER PAD
2 ± RIGHT ENGINE MOUNT
3 ± BOLTS
Fig. 20 Engine Mount Bolt Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
9 - 24 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(4) Discharge air conditioning system, if equipped.
Refer to Group 24, Heating and Air Conditioning for
procedure.
(5) Disconnect the following: air intake duct at
intake manifold, throttle cables, electrical connectors
from throttle body and air cleaner housing.
(6) Remove air cleaner housing assembly.
(7) Remove upper radiator hose and fan module.
Refer to Group 7, Cooling System for procedure.
(8) Remove lower radiator hose.
(9) Disconnect automatic transmission cooler lines
and plug, if equipped.
(10) Disconnect shift linkage, electrical connectors,
and clutch cable, if equipped with manual transaxle.
(11) Disconnect engine wiring harness.
(12) Disconnect positive cable from Power Distri-
bution Center (PDC) and ground wire from vehicle
body.
(13) Disconnect ground wire from the vehicle body-
to-engine at the right side strut tower.
(14) Disconnect heater hoses.
(15) Disconnect vacuum hose from brake booster.
(16) Disconnect coolant reserve/recovery hose.
(17) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(18) Remove power steering pump and reservoir
and set them aside.
(19) Hoist vehicle and remove right inner splash
shield.
(20) Drain engine oil.
(21) Remove front wheels.
(22) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(23) Disconnect exhaust system from manifold.
(24) Disconnect the downstream oxygen sensor
connector.
(25) Remove lower engine torque strut.
(26) Remove structural collar. Refer to procedure
in this section.
(27) Lower vehicle and remove A/C compressor.
(28) Raise vehicle enough to allow engine dolly
and cradle, Special Tools 6135 and 6710 to be
installed under vehicle.
(29) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 26). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(30) Install safety straps around the engine to cra-
dle (Fig. 26). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used.(31) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(32) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(33) Remove the upper engine torque strut.
(34) Remove right and left engine and transaxle
mount through bolts (Fig. 24) and (Fig. 25).
(35) Raise vehicle slowly until body is approxi-
mately 15 cm (6 in.) above normal engine mounting
locations.
(36) Remove generator, lower bracket, and upper
mounting bolt.
(37) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary to move the engine/transmission
assembly with the cradle to allow for removal around
body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly until vehicle is within 15
cm (6 in.) of engine mounting locations.
(2) Install generator, lower bracket, and adjusting
bolt.
(3) Continue lowering vehicle until engine/tran-
saxle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 24) and (Fig. 25). Tighten bolts to 118 N´m (87
ft. lbs.).
(4) Install upper engine torque strut. Refer to pro-
cedure in this section.
(5) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(6) Install axle shafts. Refer to Group 3, Differen-
tial and Driveline for procedure.
(7) Install structural collar. Refer to procedure in
this section tightening sequence.
Fig. 24 Right Mount Through Bolt
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
9 - 26 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)