clock DODGE NEON 2000 Service User Guide

(10) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Slide radiator down into position behind radia-
tor support (yoke).
(2) Attach air conditioning condenser to radiator, if
equipped (Fig. 25), with four mounting screws.
Tighten screws to 5.4 N´m (50 in. lbs.). Then seat the
radiator assembly lower rubber isolators into the
mounting holes provided in the lower crossmember.
(3) Install and tighten radiator isolator mounting
bracket screws to 10 N´m (90 in. lbs.) (Fig. 24). The
radiator should have clearance to move up, approxi-
mately 5±8 mm (0.20±0.31 in.) after assembled.
(4) Install lower radiator hose. Align the hose and
position the clamp so it will not interfere with engine
components.
(5) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 2 N´m (18 in. lbs.).
(6) Slide fan module down into clip(s) on lower
radiator flange (Fig. 23). Install retaining screws and
tighten to 7.5 N´m (65 in. lbs.).
(7) Connect the cooling fan motor electrical connec-
tor.
(8) Install upper radiator hose. Align the hose and
position the clamp so they will not interfere with the
engine or the hood.
(9) Connect negative cable to battery.
(10) Fill cooling system with coolant. Refer to pro-
cedure in this section.
(11) Operate engine until it reaches normal operat-
ing temperature. Check cooling system and auto-
matic transmission for correct fluid levels.
RADIATOR DRAINCOCK
REMOVAL
(1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 26) from
the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening.
(2) Tighten the draincock stem by turning clock-
wise to 2.0-2.7 N´m (18-25 in. lbs.).
COOLING FAN MODULE
All models use a single speed electric motor driven
cooling system fan. The fan module includes a motor,
fan blade, and support shroud. The module is fas-
tened to the radiator by screws.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system below upper radiator hose
level. Refer to procedure in this section.
(3) Remove upper radiator hose from radiator (Fig.
27).
(4) Disconnect fan module electrical connector.
(5) Remove fan module screws from radiator (Fig.
28).
(6) Lift fan shroud up and out of lower shroud
attachment clips.
(7) Refer to Disassembly and Assembly in this sec-
tion for fan module sub-component service proce-
dures.
Fig. 25 A/C Condenser to Radiator Mounting Screws
1 ± AIR CONDITIONING CONDENSER TO RADIATOR
MOUNTING SCREWS
2 ± LOWER ISOLATOR MOUNTS
Fig. 26 Draincock
1 ± DRAIN COCK BODY
2 ± DRAIN COCK HOUSING
7 - 22 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(2) Connect recovery hose to water outlet connec-
tor/thermostat housing (Fig. 29).
(3) Fill container to proper level. Refer to Cooling
System Refilling in this section.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Draining in this section for
procedure.
(2) Detach power cord plug from heater (Fig. 31).
(3) Loosen screw in center of heater. Remove
heater assembly (Fig. 31).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward (Fig. 31).
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Connect power cord to block heater (Fig. 31).
(5) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks.
ACCESSORY DRIVE BELTS
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
REMOVAL
(1) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be removed from
power steering pump pulley. Gently, release spring
tension on tensioner.
(2) Remove belt (Fig. 34).
INSTALLATION
(1) Install belt (Fig. 34) over all pulleys except for
the power steering pump pulley.
(2) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be installed onto
power steering pulley. Release spring tension onto
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.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 35). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
Fig. 31 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
Fig. 32 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
7 - 24 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(6) Set base aside and remove base mount ring.
INSTALLATION
(1) Position mount ring to the instrument panel
and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
(2) Connect wires to base. Orient base alignment
rib at 11 o'clock to mate the groove in mount ring at
the same location
(3) Push base into the bezel till it locks.
(4) Install cigar lighter cap and check operation of
element.
GLOVE BOX DOOR/BIN
REMOVAL
(1) Open front passenger door.
(2) Remove three glove box door hinge screws.
(3) Open glove box and remove assembly from
vehicle.
(4) Remove eight screws retaining glove box door
to bin assembly.
(5) Separate glove box door from bin and remove.
INSTALLATION
For installation, reverse the above procedures.
GLOVE BOX DOOR/BIN
REMOVAL
(1) Open front passenger door.
(2) Remove three glove box door hinge screws.
(3) Open glove box and remove assembly from
vehicle.
(4) Remove eight screws retaining glove box door
to bin assembly.(5) Separate glove box door from bin and remove.
INSTALLATION
For installation, reverse the above procedures.
GLOVE BOX SWITCH/LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Open the glove box and push the glove box
sides inward allowing the door bumpers to clear and
the box to tip forward.
(3) Reach inside the opening and squeeze the
lamp/switch retainers until they are disengage.
(4) Pull the switch/lamp rearward and remove it.
Replace the lamp. To replace the switch disconnect
wire and replace the switch.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER
CAUTION: The Instrument Cluster MUST be stored
in a face up position or damage will occur to the
gauge operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Remove both left and right A-Pillar trim covers.
(3) Remove the instrument panel top cover.
(4) Remove cluster bezel.
(5) Remove the four screws attaching cluster hous-
ing to the base panel.
(6) Pull the cluster rearward to disconnect from
base panel.
(7) Remove the cluster assembly.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove instrument panel top cover. Refer to
Instrument Panel Top Cover Removal and Installa-
tion in this section.
(2) Using a trim stick (special tool #C-4755), gently
pry up on the cluster bezel and remove from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Fig. 9 Tool For Cigar Lighter / Power Outlet
Removal
1 ± 2.5MM (3/32 INS.)
2 ± WELD
3 ± 100MM (4 INS.)
4 ± 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8E - 6 INSTRUMENT PANEL SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT CLUSTER LAMPS
WARNINGS/INDICATORS
The instrument cluster warning/indicator lamps
are all serviceable Light Emitting Diodes (LED's).
The instrument cluster must first be removed, refer
to Instrument Cluster Removal and Installation in
this section, and then the defective LED just turns
out with needle nose pliers.
ILLUMINATION LAMPS
The high beam indicator, turn signals, and illumi-
nation bulbs are also serviceable. The instrument
cluster must first be removed, refer to Instrument
Cluster Removal and Installation in this section, and
then the defective bulb and socket turns out. The
bulb locations are printed on the back cover of the
instrument cluster.
INSTRUMENT PANEL ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Push seats back to their full back position.
(3) Using a trim stick (special tool #C-4755), gently
pry out on left and right A-pillar trim moldings and
remove.
(4) Remove top cover. Refer to Top Cover Removal
and Installation in this section.
(5) Gently pull up on cluster bezel and remove
from vehicle.
(6) Gently pull rearward on left lower instrument
panel cover and remove from vehicle.
CAUTION: Lock the steering wheel in the straight
ahead position. This will prevent clockspring dam-
age when the steering wheel rotates freely.
(7) Remove steering column. Refer to Group 19
Steering, Steering Column Removal and Installation.
(8) Remove left and right instrument panel end-
caps.
(9) Remove left and right cowl side panels.
(10) Remove center console. Refer to Group 23
Body, Center Console Removal and Installation.
(11) Depress the sides of the Data Link Connector
(DLC) and remove from instrument panel reinforce-
ment.
(12) Remove four bulkhead instrument panel
retaining screws.
(13) Remove two bolts on top of the brake pedal
support bracket.
(14) Remove two center support mounting bolts.
(15) Remove left and right A-pillar mounting bolts,
two on each side.(16) Disconnect right side antenna connector.
(17) Remove left and right A-pillar door harness
connectors (Fig. 10).
(18) Disconnect two harness connectors to hvac at
right top instrument panel (Fig. 11).
Fig. 10 A-Pillar Door Harness Connector
1 ± INSTRUMENT PANEL HARNESS CONNECTOR
2 ± DOOR CHECK STRAP
3 ± DOOR HARNESS CONNECTOR
Fig. 11 Instrument Panel to HVAC Harness Connectors
1 ± HVAC HARNESS CONNECTORS
PLINSTRUMENT PANEL SYSTEMS 8E - 7
REMOVAL AND INSTALLATION (Continued)

(5) Snap the center instrument bezel in position
and install the retaining screws (Fig. 5).
(6) Install the (4) HVAC control knobs.
(7) Install the A/C outlet registers on the center
instrument bezel (Fig. 6).
INSTRUMENT PANEL ± R. H. D.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M ± PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: LOCK THE STEERING WHEEL IN THE
STRAIGHT AHEAD POSITION. THIS WILL PREVENT
CLOCKSPRING DAMAGE WHEN THE STEERING
COLUMN IS REMOVED FROM THE VEHICLE.
Fig. 7 Instrument Panel - R. H. D.
Fig. 5 Center Instrument Bezel Retaining Screws
1 ± CENTER BEZEL
2 ± CENTER BEZEL RETAINING SCREWS (BEHIND REGISTER)
Fig. 6 Center Instrument Bezel
1 ± HEAD LAMP LEVELING SWITCH
2 ± CENTER INSTRUMENT BEZEL
PLINSTRUMENT PANEL AND SYSTEMS 8E - 3
REMOVAL AND INSTALLATION (Continued)

(1) Disconnect the negative battery cable.
(2) Remove the floor console. Refer to Group 23,
Body for the procedure.
(3) Remove the right and left side instrument
panel end caps (Fig. 8). Using the finger grip feature,
pull straight away from the instrument panel to dis-
engage the (3) retaining clips.
(4) Remove the right and left side A ± pillar trims.(5) Loosen the (2) screws retaining the instrument
panel top cover. Located in the defroster grille (Fig.
9).
(6) Using the heel of both hands, lift up to unclip
and remove the instrument panel top cover.
(7) Unclip and remove the instrument cluster
bezel.
(8) Remove the (2) screws retaining the lower
steering column cover and remove the cover from the
vehicle.
(9) Remove the (2) screws retaining the steering
column shroud and remove the shroud from the vehi-
cle.
(10) Disconnect the clockspring, wiper / washer,
multi-function, ignition and if equipped, the two skim
module connections and the shift interlock cable on
automatic transaxle equipped vehicles.
(11) Remove the steering shaft coupler pinch bolt
retaining pin (Fig. 11).
CAUTION: Steering wheel must be in the locked
position before removing the coupler pinch bolt or
clockspring damage can occur.
(12) Remove the steering shaft coupler pinch bolt
(Fig. 11) and separate the shafts by pulling them
straight apart.
(13) Remove the (4) steering column retaining nuts
and remove the column from the vehicle.
(14) Pull back the weather-stripping and remove
the right and left side lower kick panels.
Fig. 8 Left Instrument Panel End Cap
1 ± INSTRUMENT PANEL END CAP
Fig. 9 I. P. Top Cover Center Retaining Screws
1 ± I. P. TOP COVER RETAINING SCREWS
2 ± I. P. TOP COVER
Fig. 10 I. P. Top Cover Left Side Retaining Screw
1 ± A-PILLAR TRIM
2 ± INSTRUMENT PANEL RETAINING BOLTS
8E - 4 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

(17) Install the A/C outlet registers in the center
instrument bezel.
(18) Install the right and left side lower kick pan-
els. Reposition the weather-strip in its original posi-
tion.
(19) Install the steering column. Torque the retain-
ing nuts to 17 N´m (150 in. lbs.).
(20) Install the steering shaft coupler pinch bolt
(Fig. 21). Torque the bolt to 28 N´m (250 in. lbs.).
(21) Install the steering shaft coupler pinch bolt
retaining pin (Fig. 21).
(22) Connect the clockspring, wiper / washer,
multi-function, ignition and if equipped, the two skim
module connections and the shift interlock cable on
automatic transaxle equipped vehicles.
(23) Install the steering column shrouds. Torque
the retaining screws to 1.4 N´m (12in. lbs.)
(24) Install the lower steering column cover.
(25) Install the instrument cluster bezel.
(26) Clip the instrument panel top cover in posi-
tion.
(27) Install the (2) screws retaining the instrument
panel top cover (Fig. 22) (Fig. 23).
(28) Install the right and left side A-pillar trims
(29) Install the right and left side instrument
panel end caps.(30) Install the floor console. Refer to Group 23,
Body for the procedure.
(31) Connect the negative battery cable.
Fig. 21 Steering Shaft Coupler Pinch Bolt
1 ± STEERING SHAFT COUPLER
2 ± STEERING SHAFT COUPLER PINCH BOLT
Fig. 22 I. P. Top Cover Center Retaining Screws
1 ± I. P. TOP COVER RETAINING SCREWS
2 ± I. P. TOP COVER
Fig. 23 I. P. Top Cover Left Side Retaining Screw
1 ± A-PILLAR TRIM
2 ± INSTRUMENT PANEL RETAINING BOLTS
8E - 8 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

AUDIO SYSTEM
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION...............1
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES......1
TESTING................................1
BENCH TEST FOR ANTENNA MALFUNCTION...7REMOVAL AND INSTALLATION
CD CHANGER............................7
FRONT DOOR SPEAKER....................8
INSTRUMENT PANEL SPEAKER(S)...........8
MAST and ANTENNA ASSEMBLY.............8
RADIO..................................9
REAR SHELF SPEAKER(S).................10
GENERAL INFORMATION
INTRODUCTION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with the vehicle.
The vehicles are equipped with an Interior (Igni-
tion Off Draw) fuse in the Power Distribution Center
located in the engine compartment. After the Interior
(IOD) fuse or battery has been disconnected the clock
will require resetting. The radio station presets have
a nonvolatile memory and will retain the preset sta-
tions after a battery disconnect.
The available radio options are:
²AM/FM Stereo Cassette w/Clock
²AM/FM/CD
²AM/FM Cassette w/CD Changer Controls and
Display
²CD/4 Disc Changer - In-Dash (used w/Radio CD
Changer Controls)
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION
The radio utilizes a ground wire plugged on to a
blade terminal and is bolted to the radio chassis.
Both connector and terminal should be securely
attached. The engine has two separate ground straps
to suppress ignition noise which may interfere with
radio reception.
²Left engine mount clip on strap
²Engine to shock tower reinforcement
Inductive type spark plug cables in the high ten-
sion circuit of the ignition system complete the inter-
ference suppression. Faulty or deteriorated spark
plug wires should be replaced.
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES
CAUTION: The CD player will only operate between
approximate temperatures of -23ÉC and +65ÉC (-10ÉF
and +145ÉF).
Whenever a radio malfunction occurs;
(1) First check FUSES:
(a) Power Distribution Center (PDC), Interior
lamp fuse, M1 - Radio Memory Feed
(b) Fuse Block:
(I) Fuse 12, Illumination in the fuse block
(II) Fuse 16, Ignition feed in the fuse block
NOTE: The vehicles are shipped with the INTERIOR
LAMP fuse disconnected.
(2) Verify, the radio wire harness are properly con-
nected before starting normal diagnosis and repair
procedures. Refer to Audio Diagnostic Charts and/or
Group 8W, Wiring Diagrams, Radio Section.
TESTING
The antenna has a short cable which connects into
the instrument panel harness. The connection is
made on the right side of the instrument panel.
Antenna performance may be tested by substitut-
ing a known good antenna. It is also possible to
check short or open circuits with an ohmmeter or
continuity light once the antenna cable is discon-
nected from the radio as follows:
(1) Continuity should be present between the
antenna mast and radio end pin of antenna cable
plug (Fig. 1).
(2) No continuity should be observed or a very
high resistance of several megohms between the
ground shell of the connector and radio end pin.
PLAUDIO SYSTEM 8F - 1

HORNS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION..........................1
DIAGNOSIS AND TESTING
HORN..................................2
HORN RELAY............................2
HORN SWITCH...........................2HORN SYSTEM TEST......................2
REMOVAL AND INSTALLATION
HORN..................................4
HORN RELAY............................4
HORN SWITCH...........................5
DESCRIPTION AND OPERATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, PASSIVE RESTRAINT SYS-
TEMS FOR STEERING WHEEL REMOVAL.
The horn circuit consists of a horn switch, horn
relay, and horn. The horn circuit feed is from the fuse
to the horn relay in the Power Distribution Center
(PDC). The PDC is mounted on the battery tray.
When the horn switch is depressed, it completes the
ground circuit. The horn relay coil closes contacts
and allows current to flow to the horn. The horn is
grounded to the headlamp ground connection (Fig. 1).
HORN SWITCH
The horn switch is mounted between the outer and
inner cover of the Driver Airbag Module (Fig. 2).
When the Driver Airbag is pressed the horn switch
makes contact to ground. The ground signal is car-
ried to the horn relay and the horn sounds.
(1) The horn switch grounds to the airbag housing.
(2) If horn does not sound check for corrosion:
²Horn wire
²Horn switch ground connected to airbag metal
housing
²Airbag to steering wheel
²Ensure horn wire is properly connected and
insulator is in place on wire
(3) Refer to Group 8W, Wiring Diagrams if wire
circuit needs to be repaired.
Fig. 1 Horn System
1 ± CLOCK SPRING
2 ± HORN RELAY
3 ± 15 AMP FUSE
4 ± HEAD LAMP GROUND
5 ± HORN
6 ± HORN SWITCH
Fig. 2 Horn Switch
1 ± AIRBAG MODULE
2 ± HORN SWITCH
PLHORNS 8G - 1

INSTALLATION
(1) Install retaining clip to cable at servo.
(2) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(3) Connect electrical connector to servo.
(4) Connect vacuum hose to servo
SPEED CONTROL SWITCH
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module (Fig. 1).
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS.
REMOVAL
(1) Turn off ignition.
(2) Remove two screws from side of each switch.
(3) Rock switch away from airbag and steering
wheel.
(4) Disconnect two-way electrical connector.
(5) Repeat for the other switch.
INSTALLATION
(1) Install switches.
(2) Connect two-way electrical connector.
(3) Install two screws to the side of each switch.
(4) Install airbag, refer to the Restraint Systems
SPEED CONTROL SERVO CABLE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the throttle cable cover.
(3) Remove speed control cable from throttle lever
by sliding clasp out of the hole (Fig. 4).
(4) Lift the retaining tab on the throttle cable and
slide cable out of bracket. Lift the retaining tab on
the speed control cable and slide cable out of bracket.
(5) Disconnect electrical connector from servo.
(6) Disconnect vacuum hose from servo
(7) Remove 2 nuts retaining bracket to servo (Fig.
3).
(8) Remove push nuts holding cable housing to
servo.
(9) Remove retaining clip holding cable to servo.
INSTALLATION
(1) Install retaining clip to cable at servo.
(2) Slide cable bell housing over servo mounting
studs.
(3) Install servo mounting studs into bracket.
(4) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(5) Connect electrical connector to servo.
(6) Connect vacuum hose to servo
(7) Rotate the throttle lever forward to the wide
open position and install speed control cable clasp.
(8) Slide speed control cable into throttle cable
bracket and engage retaining tab. Slide throttle cable
into throttle cable bracket and engage retaining tab.
(9) Install the Throttle cable cover.
(10) Connect the negative battery cable.
Fig. 3 Speed Control Servo
Fig. 4 Speed Control Cable
8H - 4 VEHICLE SPEED CONTROL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)