wipers DODGE NEON 2000 Service User Guide

2
0
1 2 33
210
MITTENT
WIPER
CONTROL
1
INTER-
563
4
6
5
TIME
DELAYWASHER/
PULSE
WIPE
WIPER
RELAY6 MAXIMUM 5 MINIMUM
WIPE/
3 HIGH 2 LOW
1 DELAY
0 OFF
WASH
SWITCH
4 MIST
1 2
543
M
WIPER
MOTOR
312C202
M
2
1
PUMP WASHER
WINDSHIELD
C1046 C6
G103 S119
V5
16
DG/YL
V5
16
DG/YL
V4
16
RD/YL
V4
16
RD/YL
V3
16
BR/WT
V3
16
BR/WT
V10
18
BR
V10
18
BR
Z1
18
BK
Z1
12
BK
4C202
V6
16
DB
FUSE
BLOCK
10A
FUSE
4
244
RUN-ACC A31
RUN-ACC V6
G204
C2025
S202
Z1
16
BK
Z1
16
BK
(8W-15-7) (8W-15-5) (8W-11-2)
(8W-11-3)
(8W-11-6)(8W-10-10) (8W-11-6)
(8W-15-11) (8W-15-11)
PL8W-53 WIPERS 8W - 53 - 3
PLI05303008W-10

(25) Turn the key to OFF and remove the scan tool
from the vehicle.
(26) Test the operation of the horn, wipers and any
other functions that are steering column operated. If
applicable, reset the radio and the clock.
(27) If the steering column is a tilt column, verify
the tilt mechanism operates properly.
(28) Road test the vehicle to ensure proper opera-
tion of the steering system and the speed control sys-
tem.
STEERING COLUMN LOWER COUPLING
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section and in STEERING
GEAR.
REMOVAL
(1) Place the steering wheel in the STRAIGHT-
AHEAD position. Using a steering wheel holder, lock
the steering wheel in place to keep it from rotating
(Fig. 21). This keeps the clockspring in the proper
orientation.
(2) Inside the passenger compartment, remove the
steering column coupling retainer pin, back off the
pinch bolt nut, and remove the steering column cou-
pling pinch bolt (Fig. 22) (the pinch bolt nut is caged
to the coupling and is not removable). Separate the
upper and lower steering column couplings.
(3) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.(4) Release the locking tab on the wiring harness
connector for the power steering fluid pressure
switch before connector removal. Remove the wiring
harness connector from the power steering fluid pres-
sure switch (Fig. 23).
(5) Remove the bolt mounting the engine torque
strut to the right forward corner of the front suspen-
sion crossmember (Fig. 24).
Fig. 21 Steering Wheel Holder
1 ± STEERING WHEEL
2 ± STEERING WHEEL HOLDER
3 ± DRIVERS SEAT
Fig. 22 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. 23 Power Steering Fluid Pressure Switch
1 ± WIRING HARNESS CONNECTOR
2 ± POWER STEERING GEAR
3 ± POWER STEERING FLUID PRESSURE SWITCH
4 ± REAR OF FRONT SUSPENSION CROSSMEMBER
19 - 38 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(10) Apply pinch weld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(11) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(12) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(13) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward molding is
flush to roof line and A-pillars (Fig. 4).
(14) Clean access urethane from exterior with
Mopart, Super Clean or equivalent.
(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(16) Install A-pillar moldings.
(17) Install cowl cover and wipers.
(18) Install inside rear view mirror.
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
REAR WINDOW
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT. BE SURE TO REFER TO THE URE-
THANE MANUFACTURER'S DIRECTIONS FOR CUR-
ING TIME SPECIFICATIONS, AND DO NOT USE
ADHESIVE AFTER ITS EXPIRATION DATE.
CAUTION: Open the left front door glass before
installing the rear window to avoid pressurizing the
passenger compartment if a door is slammed
before the urethane bonding is fully cured. Water
leaks can result
Refer to the windshield paragraph of this section
for a description of tools and adhesive systems that
are recommended for use in this procedure.
REAR WINDOW REMOVAL
(1) Remove rear window moldings.
(2) Remove upper quarter trim panel.
(3) Disconnect wire connectors from rear window
defogger.
WARNING: WEAR EYE AND HAND PROTECTION
WHEN HANDLING SAFETY GLASS. PERSONAL
INJURY CAN RESULT.
CAUTION: Do not damage body or trim finish when
cutting out glass or applying fence primer.
(4) Cut the urethane around the perimeter of the
rear window glass. Refer to Windshield section of
this group for proper procedures.
(5) Remove the rear window from the vehicle.
REAR WINDOW INSTALLATION
(1) Prepare the work area, window fence, and
glass the same way as described in the Windshield
section of this group.
(2) Place fence spacers at the locations shown (Fig.
5).
(3) Install the rear window molding on glass.
(4) Apply a 10 mm (0.4 in.) bead of urethane
around the perimeter of the glass.
(5) Install the glass in the same manner described
in the Windshield section of this group (Fig. 5).
(6) Connect rear window defogger wiring and inte-
rior trim.
(7) After urethane has cured, water test rear win-
dow to verify repair. Verify rear window defogger
operation.
Fig. 3 Work Surface Set up and Molding Installation
1 ± WINDSHIELD AND MOULDINGS
2 ± URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM
EDGE
3 ± BLOCKS
23 - 6 BODYPL
REMOVAL AND INSTALLATION (Continued)

BLOWER MOTOR RESISTOR
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed.
REMOVAL
(1) Remove windshield wipers.
(2) Remove cowl top screen.
(3) Disconnect the resistor block wiring connector
(Fig. 22).
(4) Remove/unsnap resistor block from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BLOWER MOTOR WHEEL
The blower motor wheel is only serviced with the
blower motor. The wheel and the motor are balanced
as an assembly. If the blower motor wheel requires
replacement, the blower motor must also be replaced.
Refer to blower motor for replacement procedure.
COMPRESSOR
CAUTION: Add only new lubricant when system
requires additional lubricant. Do not use old
reclaimed lubricant.
REMOVAL
The A/C compressor may be unbolted and reposi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the com-
pressor clutch/coil assembly, engine, cylinder head, or
alternator.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE
TURNED OFF. DO NOT TWIST OR KINK THE
REFRIGERANT LINES WHEN REMOVING A FULLY
CHARGED COMPRESSOR. SAFETY GLASSES
MUST BE WORN.
(1) Disconnect battery negative cable.
(2) Loosen and remove drive belts, refer to Group
7, Engine Cooling.
(3) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system. If the com-
pressor is being replaced.
(4) Disconnect compressor clutch wire lead.
(5) Remove refrigerant lines from compressor, if
necessary (Fig. 23).
(6) If system is left open place plug/cap over open
lines.
(7) Remove compressor attaching bolts (Fig. 24).
Fig. 22 Blower Motor Resistor Block
1 ± RESISTOR BLOCK
2 ± ELECTRICAL CONNECTOR
Fig. 23 A/C Compressor Lines
1 ± CONDENSER LIQUID LINE
2 ± SUCTION LINE
3 ± COMPRESSOR MANIFOLD SCREWS
4 ± COMPRESSOR
5 ± DISCHARGE LINE
24 - 22 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)