tires DODGE NEON 2000 Service User Guide

SHUDDER OR VIBRATION DURING ACCELERATION
(1) A worn or damaged driveshaft inner tripod
joint.
(2) A sticking tripod joint spider assembly (inner
tripod joint only).
(3) Improper wheel alignment. See Wheel Align-
ment in this group for alignment checking and set-
ting procedures and specifications.
VIBRATION AT HIGHWAY SPEEDS
(1) Foreign material (mud, etc.) packed on the
backside of the wheel(s).
(2) Out of balance front tires or wheels. See Group
22, Wheels And Tires for the required balancing pro-
cedure.
(3) Improper tire and/or wheel runout. See Group
22, Wheels And Tires for the required runout check-
ing procedure.
REMOVAL AND INSTALLATION
DRIVESHAFTS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the driveshaft
to prevent damage.
REMOVAL
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER±SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N´m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(1) Disconnect battery negative cable.
(2) Place transaxle in gated park.
(3) Raise vehicle on hoist.
(4) Remove wheel and tire assembly (Fig. 3).(5) Remove the driveshaft to hub and bearing
retaining nut (Fig. 4).
(6) If equipped with ABS, disconnect the front
wheel speed sensor and secure harness out of the
way.
Fig. 3 Wheel and Tire Removal
1 ± WHEEL/TIRE ASSY.
2 ± LUG NUT (5)
3 ± HUB
Fig. 4 Driveshaft Retaining Nut Removal
1 ± DRIVESHAFT
2 ± HUB
3 ± HUB NUT
PLDIFFERENTIAL AND DRIVELINE 3 - 3
DIAGNOSIS AND TESTING (Continued)

BRAKE PEDAL
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
WITH AUTOMATIC TRANSAXLE
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Place the steering wheel and tires in the
STRAIGHT-AHEAD position. Using a steering wheel
holder, lock the steering wheel in place to keep it
from rotating (Fig. 37). This keeps the clockspring in
the proper orientation.
(3) Remove the steering column coupling retainer
pin, back off the pinch bolt nut, and remove the
steering column coupling pinch bolt (Fig. 38) (the
pinch bolt nut is caged to the coupling and is not
removable). Separate the upper and lower steering
column couplings.
(4) Depress and hold the brake pedal while rotat-
ing the brake lamp switch (Fig. 39) in a counterclock-
wise direction approximately 30 degrees.
(5) Pull the switch rearward and remove it from
its mounting bracket.
(6) Remove the clip securing the power brake
booster input rod to the brake pedal (Fig. 39).
Remove the input rod from the brake pedal.
(7) Remove the two upper nuts fastening the brake
pedal bracket to the power brake booster (Fig. 40).(8) Carefully pry the tie bar running between the
two upper booster mounting studs from its plastic
retaining fasteners.
(9) Remove the two remaining nuts fastening the
brake pedal bracket to the power brake booster (Fig.
40).
Fig. 37 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 38 Steering Column Couplings
1 ± STEERING COLUMN UPPER COUPLING
2 ± PINCH BOLT
3 ± STEERING COLUMN LOWER COUPLING
4 ± BRAKE PEDAL
5 ± NUT
6 ± RETAINER PIN
Fig. 39 Brake Lamp Switch
1 ± SWITCH
2 ± CLIP
3 ± BRAKE PEDAL
4 ± CONNECTOR
5 - 24 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(10) If the vehicle is equipped with antilock
brakes, carefully push the power brake booster for-
ward until the booster contacts the ABS ICU mount-
ing bracket.
(11) If the vehicle does not have antilock brakes,
carefully push the power brake booster forward one
to two inches being careful not to stretch the brake
lines from the master cylinder to the brakes.
(12) Remove the two nuts fastening the brake
pedal bracket to the instrument panel support (Fig.
40).
(13) Carefully remove the brake pedal assembly by
pulling the pedal bracket back toward the instru-
ment panel, releasing the bracket from the booster
studs. Next, tip the bracket down past the input rod,
guiding the rod through the gap left by the missing
brace removed in Step (8). Remove the brake pedal
assembly out from under the instrument panel.
(14) The pedal can be removed from it's bracket by
grinding off the peened end of the shaft, removing
the shaft, pedal and bushings. A service parts pack-
age is available to replace these items.
INSTALLATION
(1) If the pedal has been removed from it's
bracket, install the pedal, bushings and bolt-in-shaft
on the bracket using the available service parts pack-
age.
(2) Install the brake pedal assembly by tipping the
pedal bracket and guiding the power brake booster
mounting portion up past the booster input rod.
Guide the top of the bracket onto the studs protrud-
ing from the instrument panel support (Fig. 40), then
guide the booster mounting portion onto the power
brake booster mounting studs.(3) Push the power brake booster back into mount-
ing position from under the hood.
(4) Install the two nuts fastening the brake pedal
bracket to the instrument panel support (Fig. 40).
Install the nuts all the way, but do not tighten them
at this time.
(5) Install the two lower power brake booster
mounting nuts, but do not tighten them at this time.
(6) Place the tie bar running between the two
upper booster mounting studs onto the studs with
the long flat side facing upward and the curved side
downward.
(7) Install the two upper power brake booster
mounting nuts on their studs.
(8) Tighten all four nuts fastening the brake pedal
bracket to the power brake booster to a torque of 34
N´m (300 in. lbs.).
(9) Tighten the two nuts fastening the brake pedal
bracket to the instrument panel support to a torque
of 34 N´m (300 in. lbs.).
(10) Install the power brake booster input rod on
the pin mounted on the side of the brake pedal.
Install a new retaining clip on the end of the pin
(Fig. 39). Do not reuse the old clip.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it's fully extended posi-
tion.
(11) Hold the brake lamp switch firmly in one
hand. Then using the other hand, pull outward on
the plunger of the brake lamp switch until it has
ratcheted out to its fully extended position.
(12) Mount the brake lamp switch into the bracket
using the following procedure:
²Depress the brake pedal as far down as possible.
²Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
²When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30É to lock
the switch into place.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(13) Gently pull back on the brake pedal until the
pedal stops moving. This will ratchet the switch
plunger backward to the correct adjustment position.
(14) Install the dash-to-lower coupling seal in
place over the lower coupling's plastic collar and
dash cover.
(15) Verify the front tires are still in the
STRAIGHT-AHEAD position.
Fig. 40 Brake Pedal Mounting
1 ± CLUTCH CABLE
2 ± BOOSTER MOUNTING NUTS
3 ± UPPER MOUNTING NUTS
PLBRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place the parking brake lever on the mounting
studs on the vehicle floor. Install and tighten the two
mounting nuts to a torque of 28 N´m (250 in. lbs.)
(Fig. 95).
(2) Connect the wiring harness electrical connector
on the parking brake warning lamp switch (Fig. 95).
(3) Install both rear park brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(4) Ensure that the parking brake cables are cor-
rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster.
(5) Keeping your hands clear of the automatic
adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 93), then quickly
remove it from the parking brake lever mechanism.
This will allow the park brake lever mechanism to
automatically adjust the parking brake cables.
(6) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(7) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(8) Fully apply the parking brake lever.
(9) Install the center console and its mounting
screws.
(10) Remove the blocks from the tires and wheels.
PARKING BRAKE CABLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
The procedure below applies to either of the two
rear parking brake cables.
REMOVAL
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the rear seat cushion from the vehicle.
(8) Fold the rear carpeting forward to expose the
parking brake cables at the end of the rear floor.
(9) Install the box end of a 1/2 inch wrench over
the parking brake cable retainer (Fig. 96). Push the
wrench onto the retainer until the retainer fingers
are collapsed. From under the carpeting, grasp the
parking brake cable housing and pull cable straight
out of the bracket attached to the floor.
(10) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(11) Remove the rear tire and wheel assembly
from the vehicle.
(12) On vehicles equipped with rear drum brakes,
remove the brake drum. Refer to BRAKE DRUM in
this section of this service manual group.
(13) On vehicles equipped with rear disc brakes:
²Remove the disc brake caliper guide pin bolts,
then the caliper from disc brake adapter (Fig. 97).
²Hang the caliper out of the way using a wire
hanger or cord.
²Remove the brake rotor from the rear hub and
bearing.
(14) Remove the dust cap from the rear hub and
bearing.
Fig. 95 Parking Brake Lever
1 ± MOUNTING NUTS
2 ± PARKING BRAKE LEVER
3 ± PARKING BRAKE WARNING LAMP SWITCH CONNECTOR
PLBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

(22) Install the center console and its mounting
screws.
(23) Remove the blocks from the tires and wheels.
PARKING BRAKE SHOES (REAR DISC BRAKE)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the rear tire and wheel assembly.
(3) Remove the rear disc brake caliper assembly
from the brake rotor and store it out of the way.
Refer to DISC BRAKE SHOES (REAR) in this
REMOVAL AND INSTALLATION section of this ser-
vice manual group.
(4) Remove rear brake rotor.
(5) Remove the dust cap from the rear hub and
bearing.
(6) Remove the rear hub and bearing assembly
retaining nut and washer.
(7) Remove the rear hub and bearing assembly
from the rear spindle.
(8) Remove the rear brake shoe assembly hold-
down clip (Fig. 105).(9) Turn the brake shoe adjuster wheel until the
adjuster is at shortest length.
(10) Remove the adjuster assembly from the park-
ing brake shoe assemblies (Fig. 106).
(11) Remove the lower shoe-to-shoe spring (Fig.
107).
Fig. 105 Rear Brake Shoe Hold-Down Clip
1 ± HOLD DOWN CLIP
Fig. 106 Parking Brake Shoe Adjuster Assembly
1 ± ADJUSTER
Fig. 107 Brake Shoe Lower Return Spring
1 ± LOWER SPRING
PLBRAKES 5 - 53
REMOVAL AND INSTALLATION (Continued)

(4) Insert a brake adjustment tool, or a screw-
driver, through the adjusting hole in support plate
and against the star wheel of the adjuster screw.
Move the handle of tool downward to adjust the
brake drag. Rotate the tire and wheel assembly while
adjusting the adjuster screw. Continue to adjust the
shoes until a slight drag is noticed when the tire and
wheel assembly is rotated.
NOTE: In the event the brake shoes are over-ad-
justed, the adjuster can be backed off using the fol-
lowing step. If not, proceed to step 6.
(5) If the shoes are in the over-adjusted position,
insert a thin screwdriver into brake adjusting hole
and push back the adjusting lever out of engagement
with star wheel (Fig. 127). Take care not to bend the
adjusting lever. While holding the adjusting lever out
of engagement with star wheel, back off the star
wheel until the tire and wheel assembly is free to
turn without dragging. Repeat the adjustment proce-
dure.
(6) Install adjusting hole rubber plug (Fig. 126).
(7) Repeat the above adjustment procedure to the
other side brakes.
(8) Apply and release the park brake lever one
time after the adjustment process is completed so the
parking brakes can readjust themselves to the new
brake shoe adjustment.
PARKING BRAKE SHOES (REAR DISC BRAKES)
NOTE: The parking brake shoes used in the drum-
in-hat park brake system do not automatically
adjust to compensate for brake shoe lining wear.Therefore, it is necessary to manually adjust the
parking brake shoes.
(1) Verify the parking brake lever is in the
released position.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(3) Remove the rubber plug from the adjusting
hole in the disc brake caliper adapter.
(4) Adjust the parking brakes. Use the first bullet
point for the adjustment of the left side parking
brake shoes. Use the second bullet point for the
adjustment of the right side parking brake shoes.
²Insert a medium size screwdriver through
adjustment hole in the left backing plate. Position
the screwdriver against the star wheel on the park-
ing brake shoe adjuster. Using the screwdriver,
rotate the star wheel downward until a slight drag is
noticed when turning the rear tire and wheel assem-
bly. Then, using the screwdriver, slowly rotate the
star wheel upward, backing off the adjuster, just
enough to allow the rear tire and wheel assembly to
rotate without the parking brake shoes dragging. Do
not back off the adjuster star wheel more than two
clicks past the point of no drag. The parking brake
shoe-to-drum clearance is now properly set.
²Insert a medium size screwdriver through
adjustment hole in the right backing plate. Position
the screwdriver against the star wheel on the park-
ing brake shoe adjuster. Using the screwdriver,
rotate the star wheel upward until a slight drag is
noticed when turning the rear tire and wheel assem-
bly. Then, using the screwdriver, slowly rotate the
star wheel downward, backing off the adjuster, just
enough to allow the rear tire and wheel assembly to
rotate without the parking brake shoes dragging. Do
not back off the adjuster star wheel more that two
clicks past the point of no drag. The parking brake
shoe-to-drum clearance is now properly set.
(5) Install the rubber plug in the adjusting holes of
the disc brake caliper adapter.
(6) Lower the vehicle until the rear tires are just
clearing the floor.
(7) Reach inside the vehicle and fully apply and
release the park brakes two times after adjusting the
parking brake shoes.
(8) With the parking brake lever in the fully
applied position, attempt to hand rotate each rear
tire and wheel assembly to ensure that the parking
brake shoes are working.
(9) With the parking brake lever in the released
position, hand rotate each rear tire and wheel assem-
bly to ensure that the parking brake shoes are not
dragging.
Fig. 127 Backing Off Brake Adjuster Screw
1 ± MEDIUM SCREWDRIVER
2 ± BRAKE ADJUSTING HOLE
3 ± THIN SCREWDRIVER OR WELDING ROD
5 - 62 BRAKESPL
ADJUSTMENTS (Continued)

AMBER ABS WARNING LAMP
The amber ABS warning lamp is located in the
instrument cluster. The purpose of the warning lamp
is discussed in detail below.
When the ignition key is turned to the ON posi-
tion, the amber ABS warning lamp is lit until the
CAB completes its self-tests and turns off the lamp
(approximately 4 seconds). The amber ABS warning
lamp will illuminate when the CAB detects a condi-
tion that results in the shutdown of ABS function.
The CAB sends a message to the mechanical instu-
ment cluster (MIC) instructing it to turn on the
amber ABS warning lamp.
Under most conditions, when the amber ABS warn-
ing lamp is on, only the ABS function of the brake
system is affected; The electronic brake distribution
(EBD), the base brake system and the ability to stop
the vehicle are not affected.
WHEEL SPEED SENSOR (WSS)
At each wheel of the vehicle there is one wheel
speed sensor (WSS) and one tone wheel (Fig. 3) (Fig.
4) (Fig. 5) (Fig. 6). Each front wheel speed sensor is
attached to a boss in the steering knuckle. The front
tone wheel is part of the driveshaft outboard con-
stant velocity joint. The rear wheel speed sensor is
mounted to the rear disc brake adapter. The rear
tone wheel is an integral part of the rear wheel hub
and bearing.
The wheel speed sensor operates on electronic
energy supplied by the CAB and outputs a square
wave signal whose current alternates between two
constant levels. Its frequency is proportional to the
speed of the tone wheel. The output is available as
long as the sensor is powered and its state (high or
low) corresponds to the presence or absence of tone
wheel teeth. The output signal is sent to the CAB. If
a wheel locking tendency is detected by the CAB, it
will then modulate hydraulic pressure via the HCU
to prevent the wheel(s) from locking.
Correct ABS operation is dependent on accurate
wheel speed signals. The vehicle's tires and wheels
all must be the same size and type to generate accu-
rate signals. Variations in tire and wheel size can
produce inaccurate wheel speed signals.
Improper speed sensor-to-tone wheel clearance can
cause erratic speed sensor signals. The speed sensor
air gap is not adjustable, but should be checked when
applicable. Wheel speed sensor-to-tone wheel clear-
ance specifications can be found in the SPECIFICA-
TIONS section within this section in this service
manual group.
ELECTRONIC BRAKE DISTRIBUTION
Vehicles equipped with ABS use electronic brake
distribution (EBD) to balance front-to-rear braking.The EBD is used in place of a rear proportioning
valve. The EBD system uses the ABS system to con-
trol the slip of the rear wheels in partial braking
range. The braking force of the rear wheels is con-
trolled electronically by using the inlet and outlet
valves located in the integrated control unit.
Upon entry into EBD the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure, the outlet valve for
Fig. 3 Left Front Wheel Speed Sensor
1 ± LEFT FRONT WHEEL SPEED SENSOR
2 ± TONE WHEEL
Fig. 4 Right Front Wheel Speed Sensor
1 ± RIGHT FRONT WHEEL SPEED SENSOR
2 ± TONE WHEEL
PLBRAKES 5 - 69
DESCRIPTION AND OPERATION (Continued)

ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID
VALVE, AND SHUTTLE VALVE FUNCTION (ABS
WITH TRACTION CONTROL)
The hydraulic diagram (Fig. 8) shows the vehicle in
the ABS braking mode. The diagram shows one
wheel is slipping because the driver is attempting to
stop the vehicle at a faster rate than is allowed by
the surface on which the tires are riding.
²The hydraulic shuttle valve closes upon brake
application so that the pump/motor cannot siphon
brake fluid from the master cylinder.²The normally open and normally closed valves
modulate (build/decay) the brake hydraulic pressure
as required.
²The pump/motor is switched on so that the
brake fluid from the low pressure accumulators is
returned to the master cylinder circuits.
²The brake fluid is routed to either the master
cylinder or the wheel brake depending on the posi-
tion of the normally open valve.
Fig. 8 ABS With Traction Control - ABS Braking Hydraulic Circuit
1 ± OUTLET VALVE
2 ± PUMP PISTON
3 ± PUMP MOTOR (ON)
4 ± SUCTION VALVE
5 ± LOW PRESSURE ACCUMULATOR
6 ± NORMALLY CLOSED VALVE (MODULATING)
7 ± TO RIGHT FRONT WHEEL
8 ± NORMALLY OPEN VALVE (MODULATING)9 ± NORMALLY OPEN ASR VALVE (OFF)
10 ± FROM MASTER CYLINDER
11 ± HYDRAULIC SHUTTLE VALVE
12 ± MASTER CYLINDER PRESSURE
13 ± CONTROLLED WHEEL PRESSURE
14 ± LOW PRESSURE ACCUMULATOR PRESSURE
15 ± PUMP INTERSTAGE PRESSURE
16 ± NOISE DAMPER CHAMBER
5 - 72 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

VEHICLE SPEED CONTROL SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
SPEED CONTROL SYSTEM.................1
SPEED CONTROL SERVO-PCM OUTPUT.......2
SPEED CONTROL SWITCHESÐPCM INPUT....2
STOP LAMP SWITCH......................3
SERVO CABLE...........................3
VACUUM RESERVOIR.....................3VEHICLE SPEED SENSOR..................3
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO...................3
SPEED CONTROL SWITCH..................4
SPEED CONTROL SERVO CABLE.............4
VACUUM RESERVOIR.....................5
DESCRIPTION AND OPERATION
SPEED CONTROL SYSTEM
OPERATION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the Powertrain Control Module
which is located in the engine compartment. The con-
trols are located on the steering wheel and consist of
five switches. The ON, OFF and SET buttons are
located on the left side of the airbag module. The
RESUME, ACCEL, COAST and CANCEL buttons
are located on the right side of the airbag module
(Fig. 1).
The system is designed to operate at speeds above
25 mph (40 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
The speed control can be disengaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
The speed control can be disengaged also by any of
the following conditions:
²An indication of Park or Neutral
²The VSS signal increases at a rate of 10 mph
per second (indicates that the co-efficient of friction
between the road surface and tires is extremely low)
²Depressing the clutch pedal.
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)²The VSS signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate)
²If the actual speed is not within 20 mph of the
set speed
The previous disengagement conditions are pro-
grammed for added safety.
Fig. 1 Speed Control Switch
1 ± SPEED CONTROL SWITCHES
2 ± RES ACCEL
3 ± CANCEL
4 ± COAST
5 ± SET
6 ± ON/OFF
PLVEHICLE SPEED CONTROL SYSTEM 8H - 1

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)