clock DODGE NEON 2000 Service Service Manual

8W-43 AIRBAG SYSTEM
Component Page
Airbag Control Module..............8W-43-2, 3
Clockspring.........................8W-43-3
Data Link Connector.................8W-43-2
Driver Airbag.......................8W-43-3
Fuse 5 (FB).........................8W-43-2
Fuse 8 (FB).........................8W-43-2
Fuse 9 (FB).........................8W-43-2
Fuse 10 (FB)........................8W-43-2Component Page
Fuse 11 (FB)........................8W-43-2
Fuse 12 (FB)........................8W-43-2
Fuse Block.........................8W-43-2
G202..............................8W-43-2
Instrument Cluster...................8W-43-2
Passenger Airbag....................8W-43-3
Powertrain Control Module............8W-43-2
PL8W - 43 AIRBAG SYSTEM 8W - 43 - 1

12
43
AIRBAG PASSENGER
AIRBAG DRIVER
CLOCKSPRING
8756
MODULE CONTROL
AIRBAG
PASSENGER
AIRBAG
LINE 1 LINE 2AIRBAG PASSENGER DRIVER
AIRBAG
LINE 1 LINE 2 AIRBAG DRIVER
PAIR TWISTED
PAIR TWISTED
PAIR TWISTED
PASSENGER
AIRBAG
LINE 2 LINE 1 AIRBAG PASSENGER DRIVER
AIRBAG
LINE 2 LINE 1AIRBAG DRIVER BK
R43
18
BK/LBR45
18
DG/LB
BK
R42
18
BK/YLR44
18
DG/YL
12
PL8W-43 AIRBAG SYSTEM 8W - 43 - 3
PLI04303008W-10

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................8W-80-4
A/C Cycling Switch...................8W-80-4
A/C Heater Blower Motor..............8W-80-4
A/C Heater Control...................8W-80-4
A/C High Pressure Switch.............8W-80-4
A/C Low Pressure Switch..............8W-80-5
Airbag Control Module................8W-80-5
Back-Up Lamp Switch................8W-80-5
Blower Motor Resistor Block...........8W-80-6
Brake Lamp Switch..................8W-80-6
Brake Shift Interlock Solenoid..........8W-80-6
Brake Warning Indicator Switch........8W-80-6
C101..............................8W-80-7
C102..............................8W-80-7
C103..............................8W-80-8
C104..............................8W-80-9
C105.............................8W-80-10
C106.............................8W-80-10
C107.............................8W-80-10
C108.............................8W-80-10
C109.............................8W-80-11
C110 .............................8W-80-11
C111 .............................8W-80-11
C201.............................8W-80-12
C202.............................8W-80-13
C203.............................8W-80-13
C204.............................8W-80-13
C205.............................8W-80-14
C301.............................8W-80-15
C302.............................8W-80-15Component Page
C303.............................8W-80-15
C304.............................8W-80-15
C305..........................8W-80-16, 17
C306.............................8W-80-17
Camshaft Position Sensor.............8W-80-18
Cargo Lamp.......................8W-80-18
Center High Mounted Stop Lamp.......8W-80-18
Center Stack Lamp..................8W-80-18
Cigar Lighter/Power Outlet............8W-80-18
Clockspring........................8W-80-19
Clutch Interlock Switch..............8W-80-19
Controller Anti-Lock Brake............8W-80-19
Crankshaft Position Sensor............8W-80-20
Data Link Connector.................8W-80-20
Decklid Solenoid....................8W-80-20
Dome Lamp.......................8W-80-20
Dome Lamp/Intrusion Sensor..........8W-80-21
Driver Airbag......................8W-80-21
Driver Cylinder Lock Switch...........8W-80-21
Driver Door Lock Motor..............8W-80-21
Driver Door Lock Switch..............8W-80-21
Driver Power Mirror.................8W-80-22
Driver Power Window Motor...........8W-80-22
Driver Power Window Switch..........8W-80-23
Engine Coolant Temperature Sensor.....8W-80-23
Engine Oil Pressure Switch...........8W-80-24
Fuel Injector No. 1..................8W-80-24
Fuel Injector No. 2..................8W-80-24
Fuel Injector No. 3..................8W-80-24
Fuel Injector No. 4..................8W-80-24
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

CAV CIRCUIT FUNCTION
1 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2
3B9 18RD
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
CONTROLLER
ANTI-LOCK
BRAKE
BLACK
23 17 1
7
8
924
25 1610
D25 18VT/YLF12 18DB/WT
Z1 12BK GROUND
FUSED B(+) A20 12RD/DB12-VOLT SUPPLY
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
PCI BUS
L50 18WT/TN
B6 18WT/DB
B7 18WT
B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
Z1 12BK GROUNDBRAKE LAMP SWITCH OUTPUT
FUSED B(+) A10 12RD/DG--
--
--
---
B3 18LG/DB
18LG B4 LEFT REAR WHEEL SPEED SENSOR (-)
12-VOLT SUPPLY
- -
B27 18RD/YL TRACTION CONTROL SWITCH SENSE
-
B2 18YL
12-VOLT SUPPLY 12-VOLT SUPPLY RIGHT FRONT WHEEL SPEED SENSOR (-)-
(MTX) SWITCH
CLUTCH INTERLOCK SWITCH SENSE T141 20YL/RD 3
1
3
INTERLOCKCLUTCH
GROUND Z1 18BK 2CLUTCH SWITCH K119 20LG/BK 1
FUNCTION CIRCUIT CAV
BLACK
-
- -
-
-
SPEED CONTROL
CLOCKSPRING5
6
7 3
4 2 1CIRCUIT CAV
1
7
X3 22BK/RD-
-
FUNCTION
DRIVER AIRBAG LINE 2
DRIVER AIRBAG LINE 1 R43 18BK/LB
R45 18DG/LB
V37 20RD/LG
Z10 20BK/TNSPEED CONTROL SWITCH SIGNAL HORN RELAY CONTROL
GROUND-
- GREEN
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19
PLI08019008W-10

Connector
Name/NumberColor Location Fig.
C204 RD Left Side of
Instrument
Panel6, 8, 9
C205 GY Left Side of
Instrument
Panel6, 8,
14
C301 RD Right C-Pillar 11
C302 BK Inner Left
Rear Quarter
Panel11
C303 BL/BK Left B-Pillar at
Rear Door10, 16
C304 BL/BK Right B-Pillar
at Rear Door12, 16
C305 NAT Left Side of
Instrument
Panel6, 8,
10
C306 BK Front Center
of Headliner9
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf11
Center High
Mounted Stop
LampBK Rear of Lamp 17
Center Stack
LampBK Center of
Instrument
Panel7
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel7
Clockspring GN Rear of
Steering
Wheel6
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal2
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower2
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK At Left Kick
Panel Area2Connector
Name/NumberColor Location Fig.
Decklid
SolenoidBK On Decklid 17
Dome Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Dome
Lamp/Intrusion
Sensor
(Built-Up-
Export)NAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door14
Driver Door
Lock MotorBK At Drivers
Door14
Driver Door
Lock SwitchBK At Drivers
Door14
Driver Power
MirrorGY At Drivers
Door14
Driver Power
Window MotorBK At Drivers
Door14
Driver Power
Window
Switch - C1BK At Drivers
Door14
Driver Power
Window
Switch - C2GY At Drivers
Door14
Engine
Coolant
Temperature
SensorBK Right Front of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine5
Fuel Injector
NO.1BK At Injector 4
Fuel Injector
NO. 2BK At Injector 4
Fuel Injector
NO. 3BK At injector 4
Fuel Injector
NO. 4BK At Injector 4
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
C303 BL/BK Left B-Pillar at
Left Rear
Door28, 35
C304 BL/BK Right B-Pillar
at Right Rear
Door29, 31,
35
C305 NAT Right Side of
Instrument
Panel25, 26,
29
C306 BK Front Center
of Headliner27
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf30
Center High
Mounted Stop
LampBK Rear of Lamp 36
Center Stack
LampBK Center of
Instrument
Panel24
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel24
Clockspring GN Rear of
Steering
Wheel25
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal23
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower19
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK Right Front
Kick Panel23
Decklid
SolenoidBK On Decklid 36
Dome
Lamp/Intrusion
SensorNAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door34
Driver Door
Lock MotorBK At Drivers
Door34Connector
Name/NumberColor Location Fig.
Driver Door
Lock SwitchBK At Drivers
Door34
Driver Power
MirrorBL At Drivers
Door34
Driver Power
Window MotorBK At Drivers
Door34
Driver Power
Window
Switch - C1BK At Drivers
Door34
Driver Power
Window
Switch - C2GY At Drivers
Door34
Engine
Coolant
Temperature
SensorBK Right Side of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine22
Fuel Injector
NO. 1BK At Injector 21
Fuel Injector
NO. 2BK At Injector 21
Fuel Injector
NO. 3BK At injector 21
Fuel Injector
NO. 4BK At Injector 21
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment20
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel24, 26
8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

(11) Inserta8mmAllen wrench into the hexagon
opening located on the front of the belt tensioner pul-
ley (Fig. 72). Rotate the pulley counterclockwise until
it contacts the stop. While holding tensioner pulley
against stop, insert a 1/8º or 3 mm diameter pin or
Allen wrench through the hole located to the left of
the hex opening (Fig. 72). While pushing pin into
hole, allow the tensioner pulley to rotate back.
Almost immediately, the pin should engage the lock-
ing hole to prevent further movement of the pulley.
(12) Remove timing belt.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
Fig. 68 Camshaft Timing Marks
1 ± CAM SPROCKET TIMING MARK
2 ± ARROW ON REAR COVER
Fig. 69 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 6827±A INSERT
2 ± SPECIAL TOOL 1026 THREE JAW PULLER
Fig. 70 Right Engine Mount Bracket
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET ASSEMBLY
Fig. 71 Timing Belt Cover
1 ± ACCESS PLUG
2 ± BOLTS
9 - 44 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(17) Install rear timing belt cover and camshaft
sprocket.
(18) Install crankshaft sprocket, timing belt ten-
sioner, timing belt, and cover.
(19) Install front engine mount bracket.
(20) Remove engine from repair stand and position
on Special Tools 6135 and 6710 Engine Dolly and
Cradle. Install safety straps around the engine to
cradle and tighten and lock them into position.
(21) Install crankshaft rear oil seal. Refer to proce-
dure in this section.
(22) Install drive plate/flywheel. Apply Mopart
Lock & Seal Adhesive to bolt threads and tighten to
95 N´m (70 ft. lbs.).
(23) Install transaxle to engine.
(24) Install structural collar. Refer to procedure in
this section.
(25) Install engine assembly. Refer to procedure in
this section.
(26) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ring is in the groove on adapter. Align
roll pin into engine block and tighten assembly to 80
N´m (60 ft. lbs.) (Fig. 101).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 102),
avoid deforming the filter. Use an appropriate oil fil-
ter removing tool. Position filter wrench strap close
the seam at the base of the filter. The oil filter seam
that joins the can to the base, is reinforced by the
base plate.
(1) Turn filter counterclockwise to remove.
(2) Clean and check the filter mounting surface.
The surface must be smooth, flat and free of debris
or old pieces of rubber.
(3) To install, lubricate new filter gasket. Screw fil-
ter on until gasket contacts base. Tighten to 21 N´m
(15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(3) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(4) Remove oil pan. Refer to procedure in this sec-
tion.
(5) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 103).
(6) Remove oil pick-up tube.
(7) Remove oil pump (Fig. 104) and front crank-
shaft seal.
Fig. 101 Engine Oil Filter Adapter to Engine Block
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 102 Engine Oil Filter
1 ± OIL FILTER
2 ± DRAIN PLUG
PL2.0L SOHC ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 15).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Install fuel tank, refer to the Fuel Tank remov-
al/installation section.
(6) Lower vehicle.
(7) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL FILTER/FUEL
PRESSURE REGULATOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 16) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 17).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 15 Fuel Tank Locknut
1 ± SPECIAL TOOL 6856
2 ± LOCKNUT
Fig. 16 Locking Spring Tab
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
Fig. 17 Spring Tab In Locating Slot
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
PLFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Damaged, mis-positioned or
un-lubricated steering column
coupler to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding upper strut bearing. 7. Disassemble strut assembly. Correct
binding condition in strut bearing or replace
bearing.
8. Tight shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on front
suspension crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling worn,
broken or loose.3. Replace steering column coupling.
4. Free play in steering column. 4. Check all components of the steering
system and repair or replace as required.
5. Worn control arm ball joints. 5. Replace ball joint or control arm as
required.
6. Loose steering knuckle to ball joint
stud pinch bolt.6. Inspect pinch bolts, replace as
necessary, and tighten to specified torque.
7. Front wheel bearings loose or
worn.7. Replace wheel bearing or knuckle as
necessary.
8. Loose outer tie rod ends. 8. Replace outer tie rod ends that have
excessive free play.
9. Loose inner tie rod ends. 9. Replace power steering gear.
10 Defective steering gear rotary
valve.10. Replace power steering gear.
NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering system
repairs. Shudder should dissipate after the vehicle
has been driven several weeks.
NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note thefollowing. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in either
direction and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
19 - 8 STEERINGPL
DIAGNOSIS AND TESTING (Continued)