ABS DODGE NEON 2000 Service Workshop Manual

DESCRIPTION AND OPERATION
HEADLAMP SWITCH
The headlamp switch is part of the Multi-Function
Switch. Refer to Group 8J, Turn Signal and Flasher
for the Multi-Function Switch Test, Removal and
Installation procedures.
INSTRUMENT CLUSTER
There are two conventional instrument cluster
assemblies available. The clusters electronically drive
the speedometer, odometer, gauges, and tachometer
(if equipped). Refer to (Fig. 2) and (Fig. 3).
The instrument cluster controls the courtesy
lamps, it receives and sends messages to other mod-
ules via the PCI bus circuit, it controls all the instru-
ment illumination and the chime is also an integral
part of the cluster. The front turn signals are wired
through the cluster and then go to the front lamps.
The reason being that the DRL module is built into
the cluster (if equipped).
All gauges in the electronic clusters are the analog
type gauges. When the ignition switch is moved to
the OFF position, the cluster drives each gauge to its
lowest position. The individual gauges are not servi-
cable and require complete replacement of the cluster
if one or more gauges are inoperable.
One button is used to switch the display from trip
to total mileage. Holding the button when the display
is in the trip mode will reset the trip mileage. This
button is also used to put the cluster in self-diagnos-
tic mode. Refer to Service Procedures, Cluster Self-
Diagnostics in this section. Most of the indicators will
come on briefly for a bulb heck when the ignition is
turned from OFF to ON. All of the LED's are replace-
able.
In the event that the instrument cluster looses
communication with all other modules on the PCI
bus, the cluster will display ªnobusº in the VF dis-
play. The VF display also displays ªDoorº, ªCruiseº,
ªTracº, and odometer trip or total.
If the cluster does not detect voltage on the cour-
tesy lamp circuit, the message ªFUSEº will alternate
with the odometer/trip odometer for 30 seconds after
the ignition is turned on and for 15 seconds after the
vehicle is first moved. The lack of voltage can be due
to the M1 Fused B(+) (IOD) fuse being open, a bad or
missing courtesy lamp bulb, or a circuit problem.
WARNING AND INDICATOR LAMPS
The instrument cluster has warning lamps and
indicators for the following systems:
²Airbag
²Anti-lock Brakes (ABS) if equipped
²Brake warning
²Charging System²Front fog lamps (if equipped)
²High beam indicator
²Low fuel (premium cluster only)
²Low oil pressure
²Malfunction indicator (service engine soon) lamp
²Right and left turn signals
²Seat belt warning
²Security system
²Trac-Off (ABS equipped vehicles only)
The instrument cluster has a Vacuum Fluorescent
(VF) display for the following systems:
²Cruise
²Door (ajar)
²Odometer
²Set (cruise)
²Trac
²Trip
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM
For testing of this system refer to Group 8M, Pas-
sive Restraint Systems.
BRAKE SYSTEM WARNING LAMP TEST
The brake warning lamp illuminates when the
parking brake is applied with ignition switch turned
to the ON position. The same lamp will also illumi-
nate if one of the two service brake systems fail the
when brake pedal is applied.
To test the system:
²As the ignition switch is turned to the start posi-
tion the lamp should light.
²Turn ignition switch to the ON position and
apply the parking brake. The lamp should light.
If lamp fails to light inspect for:
²A burned out lamp
²Loose, corroded or damaged socket
²A damaged circuit board
²A broken or disconnected wire at the switch
²Defective switch
To test the service brake warning system, refer to
Group 5, Brakes, Hydraulic System Control Valves.
INSTRUMENT CLUSTER LAMPS
Every time the vehicle is switched to the START/
RUN position, the cluster goes through a BULB
CHECK. This tests most of the indicator lamps and
Vacuum Fluorescent (VF) displays. If only one lamp
is out, remove the instrument cluster and replace the
defective bulb or Light Emitting Diode (LED). If
some or all of the lamps fail to light, refer to the
proper Body Diagnostics Procedures Manual.
8E - 2 INSTRUMENT PANEL SYSTEMSPL

To diagnose the cluster lamps first place the clus-
ter in self-diagnostic mode. With the ignition switch
in the off position, press the trip odometer reset but-
ton down. Simultaneously turn the ignition key to
the ON position and release the trip reset button. All
the indicator lamps and VF displays should illumi-
nate except for the fog lamp, turn signal, and high
beam select indicators. Refer to (Fig. 2), (Fig. 3), and
the Cluster Identification table.
1 ± FOG LAMP
2 ± BRAKE**
3 ± TRAC OFF**
4 ± ABS**
5 ± SPEEDOMETER
6 ± LEFT/RIGHT TURN SIGNAL
7 ± HIGH BEAM
8 ± TACHOMETER
9 ± OIL PRESSURE**
10 ± SEAT BELT**
11 ± BATTERY**
12 ± AIR BAG**
13 ± SECURITY*
14 ± FUEL FILLER DOOR LOCATOR
15 ± FUEL GAUGE
16 ± LOW FUEL*
17 ± MALFUNCTION INDICATOR LAMP (MIL)**
18 ± TRIP RESET BUTTON
19 ± TRAC**
20 ± ODOMETER**
21 ± DOOR (AJAR)**
22 ± SET CRUISE*
23 ± TRIP**
24 ± CRUISE*
25 ± TEMPERATURE GAUGE
*ILLUMINATE DURING SELF-DIAGNOSTICS
**ILLUMINATE DURING BULB CHECK AND SELF-DIAGNOSTICS
LOW OIL PRESSURE WARNING LAMP TEST
The low oil pressure warning lamp will illuminate
when the ignition switch is turned to the ON position
without engine running. The lamp also illuminates if
the engine oil pressure drops below a safe oil pres-
sure level.To test the system, turn the ignition switch to the
ON position. If the lamp fails to light, inspect for a
broken or disconnected wire at the oil pressure
switch, located at the front of the engine (Fig. 4). If
the wire at the connector checks good, pull the con-
nector loose from the switch and with a jumper wire,
ground the connector to the engine. With the ignition
switch turned to the ON position, check the warning
lamp. If the lamp still fails to light, inspect for a
burned out lamp or disconnected socket in the clus-
ter.
Fig. 2 Base Instrument Cluster Without Tachometer
Fig. 3 Premium Instrument Cluster With Tachometer
1 ± FOG LAMP
2 ± BRAKE**
3 ± TRAC OFF**
4 ± ABS**
5 ± SPEEDOMETER
6 ± LEFT/RIGHT TURN SIGNAL
7 ± HIGH BEAM
8 ± TACHOMETER
9 ± OIL PRESSURE**
10 ± SEAT BELT**
11 ± BATTERY**
12 ± AIR BAG**
13 ± SECURITY*
14 ± FUEL FILLER DOOR LOCATOR
15 ± FUEL GAUGE
16 ± LOW FUEL*
17 ± MALFUNCTION INDICATOR LAMP (MIL)**
18 ± TRIP RESET BUTTON
19 ± TRAC**
20 ± ODOMETER**
21 ± DOOR (AJAR)**
22 ± SET CRUISE*
23 ± TRIP**
24 ± CRUISE*
25 ± TEMPERATURE GAUGE
*ILLUMINATE DURING SELF-DIAGNOSTICS
**ILLUMINATE DURING BULB CHECK AND SELF-DIAGNOSTICS
PLINSTRUMENT PANEL SYSTEMS 8E - 3
DIAGNOSIS AND TESTING (Continued)

The accessory switches are not serviced separately,
but the cigar lighter/power outlet is and must be
transferred to the new bezel. Refer to Cigar Lighter/
Power Outlet Removal and Installation in this sec-
tion.
INSTALLATION
For installation reverse the above procedures.
CENTER CONSOLE FLOOD LAMP
REMOVAL
(1) Insert a small screwdriver into notch by lens
and gently pry out unit. Refer to (Fig. 7).
(2) Slide back rear cover to expose bulb.
(3) Replace bulb.
INSTALLATION
For installation reverse the above procedures.
When installing the retainer ensure that the forward
tabs are inserted properly into the slots in the instru-
ment panel.
CIGAR LIGHTER / POWER OUTLET ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Look inside and note position of the retaining
bosses (Fig. 8).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 9).
(5) Disconnect the base wires.
Fig. 6 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
Fig. 7 Accessory Switch/Power Outlet Bezel
1 ± REAR WINDOW DEFOGGER
2 ± TRACTION CONTROL SWITCH
3 ± CIGAR LIGHTER/AUXILIARY POWER OUTLET
Fig. 8 Cigar Lighter / Power Outlet Base Removal
1 ± RETAINING BOSSES-ENGAGE PLIERS HERE
2 ± PARTIALLY REMOVED
3 ± EXTERNAL SNAP-RING PLIERS
4 ± PULL BASE OUT-THROUGH MOUNTING RING
PLINSTRUMENT PANEL SYSTEMS 8E - 5
REMOVAL AND INSTALLATION (Continued)

(28) Remove the (2) I. P. retaining bolts which
attach the I. P. to the body at the tunnel bracket
(Fig. 13).
(29) Remove the (4) I. P. retaining bolts from the
right and left side body side cowls (Fig. 14) (Fig. 15).(30) With assistance from another person, guide
the HVAC control head through the I. P. opening
while removing the instrument panel.
INSTALLATION
(1) Before installing the instrument panel, be cer-
tain the (2) I. P. wire harness connector retaining
screws have been removed. The wire bundle should
hang between the two connector mounting tabs on
the I. P. casting (Fig. 16).
(2) With assistance from another person, guide the
HVAC control head through the I. P. opening while
installing the instrument panel.
(3) Install the (4) I. P. retaining bolts on the right
and left side body side cowls (Fig. 17) (Fig. 18).
Torque the bolts to 28 N´m (250 in. lbs.).
(4) Install the (2) I. P. retaining bolts which attach
the I. P. to the body at the tunnel bracket (Fig. 19).
Torque the bolts to 28 N´m (250 in. lbs.).
(5) Install the I. P. retaining fasteners on top of
the I. P. Torque the nuts to 12 N´m (105 in. lbs.).
(6) Connect the radio antenna.
(7) Connect the left front door wire harness and
reposition the sealing boot in its original position.
(8) Connect the right front door wire harness and
reposition the sealing boot in its original position.
(9) Clip the wire harness along the center console
and connect the airbag control module, parking brake
and the PRNDL lamp if equipped.
Fig. 14 Right I. P. Retaining Bolts
1 ± INSTRUMENT PANEL RETAINING BOLTS
Fig. 15 Left I. P. Retaining Bolts
1 ± A-PILLAR TRIM
2 ± INSTRUMENT PANEL RETAINING BOLTS
Fig. 16 I. P. Wire Harness Connector
1 ± I. P. CONNECTOR MOUNTS
2 ± TOP OF PANEL
3 ± I/P CONNECTOR
4 ± RETAINING SCREWS
8E - 6 INSTRUMENT PANEL AND SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

HORN SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 5).
(2) Remove the Driver Airbag Module. Refer to
Group 8M Passive Restraint Systems, Driver Airbag
Module Removal and Installation.
(3) Clip off strap tie holding the horn switch wire
to the airbag module.
(4) Unclip horn switch wire connector from airbag
module.(5) Remove four torx screws from top side of air-
bag module.
(6) Fold airbag module cover down to expose the
horn switch.
(7) Lift the horn switch off indexing tabs and
remove from vehicle.
INSTALLATION
For installation, reverse the above procedures.
PLHORNS 8G - 5
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Push bulb in socket and snap into place.
(2) Install floor console.
GLOVE BOX LAMP BULB
REMOVAL
(1) Open glove box door.
(2) Pull downward on lamp/switch assembly to dis-
engage tabs from instrument panel.
(3) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Place lamp/switch assembly into position.
(3) Push lamp/switch assembly to lock tabs.
(4) Check lamp operation, and close glove door.
FLOOR CONSOLE LAMP BULB
REMOVAL
(1) Using a flat bladed tool, slide it between the
lamp and instrument panel to disengage tabs.(2) Remove bulb from lamp socket.
INSTALLATION
(1) Install bulb into socket.
(2) Place lamp into position.
(3) Push lamp to lock tabs.
(4) Check lamp operation.
VISOR VANITY LAMP BULB
REMOVAL
(1) Lower visor.
(2) Insert a small flat bladed tool between the
lamp lens and lamp.
(3) Carefully pry lens outward.
(4) Remove bulb from socket.
INSTALLATION
(1) Position bulb in socket and snap into place.
(2) Position lens on lamp and snap into place.
PLLAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position lamp on hood and install screw.
(2) Connect lamp wire connector.
(3) Install lamp bulb.
(4) Install lens lamp.
(5) Close hood.
REAR CARGO LAMP
REMOVAL
(1) Insert a trim stick or small flat blade between
the lamp lens and rear shelf reinforcement panel.
(2) Pry the lamp lens downward.
(3) Disconnect wire connector.
(4) Remove lamp from vehicle.
INSTALLATION
(1) Place lamp into position.
(2) Connect wire connector.
(3) Install lamp lens.
DOME LAMP
REMOVAL
(1) Insert a trim stick between the dome lamp
bezel and dome lamp lens. Carefully pry down on one
side of the lamp lens.(2) Carefully pull down on lamp lens to remove
lamp from headliner.
(3) Disconnect wire connector.
(4) Remove lamp from vehicle.
INSTALLATION
(1) Place lamp into position.
(2) Connect wire connector.
(3) Install dome lamp and lens.
GLOVE BOX LAMP BULB
REMOVAL
(1) Open glove box door.
(2) Pull downward on lamp/switch assembly to dis-
engage tabs from instrument panel.
(3) Pull bulb from socket.
(4) Disconnect wire connector from lamp and
remove glove box lamp/switch.
INSTALLATION
(1) Push bulb into socket.
(2) Place lamp/switch assembly into position.
(3) Connect wire connector to the lamp/switch.
(4) Push lamp/switch assembly to lock tabs.
(5) Check lamp operation, and close glove door.
FLOOR CONSOLE LAMP BULB
REMOVAL
(1) Using a flat bladed tool, slide it between the
lamp and instrument panel to disengage tabs.
(2) Remove bulb from lamp socket.
INSTALLATION
(1) Install bulb into socket.
(2) Place lamp into position.
(3) Push lamp to lock tabs.
(4) Check lamp operation.
VISOR VANITY LAMP
The visor vanity lamp is incorporated in the visor
assembly. Replace the visor if the lamp has failed.
Fig. 5 License Plate Lamp
1 ± LICENSE PLATE LAMP
2 ± BULB
PLLAMPS 8L - 15
REMOVAL AND INSTALLATION (Continued)

BULB APPLICATION
TABLE OF CONTENTS
page page
SPECIFICATIONS
EXTERIOR LAMPS........................17INTERIOR LAMPS........................17
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the chart below.
Damage to lamp can result. Do not touch halogen
bulbs with fingers or other oily surfaces. Bulb life
will be reduced.
LAMP BULB
Back Up Lamp................3157 ± P27/7W
Center High Mounted Stop Lamp
(CHMSL).........................W16W
Front Fog Lamp..................... GE881
Front Park/Turn Signal Lamp..........3157NA
Front Side Marker Lamp................. 168
Headlamp............................9007
License Plate Lamp..................... 168
Rear Tail/Stop/
Turn Signal Lamp............3157 ± P27/7W
INTERIOR LAMPS
Service procedures for most of the lamps in the
instrument panel, Instrument cluster and switches
are located in Group 8E, Instrument Panel and
Gauges.
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the chart below.
Damage to lamp can result.LAMP BULB
ABS Indicator......................... LED
Airbag Indicator....................... LED
Brake System Warning Indicator.......... LED
Climate Controls....................... LED
Console Gear Selector W/Auto...........PC194
Dome Lamp..........................T579
Floor Console Lamp..................... T37
Front Fog Lamp Indicator................ LED
Glove Compartment....................T194
High Beam Lamp Indicator.............PC194
Ignition Lock........................... 161
Instrument Cluster Illumination.........PC194
Low Fuel Indicator..................... LED
Low Oil Pressure Indicator............... LED
Rear Cargo...........................T906
Seat Belt Indicator..................... LED
Security Alarm Indicator................. LED
Malfunction Indicator Light.............. LED
TRAC OFF Indicator.................... LED
Turn Signal Indicator..................PC194
Underhood............................ 105
Visor Vanity........................6501966
Voltage Indicator....................... LED
All the inside bulbs brass or glass wedge base. Alu-
minum base bulbs are not approved and should not
be used for replacement.
PLLAMPS 8L - 17

(4) Push the rear fog lamp assembly into the
bumper cover and install the (2) retaining screws
(Fig. 16).
SIDE REPEATER LAMP BULB
REMOVAL
(1) Remove the screws and pushpins securing the
appropriate front wheel splash shield. Reach between
the fender and splash shield to access the rear of the
side repeater lamp. Depress the top and bottom
retaining tabs to release the lamp from the fender
(Fig. 17).
(2) Rotate the side repeater lamp socket clockwise
and remove the lamp from the lamp housing
(Fig. 18).
(3) Pull the lamp bulb from the lamp socket.
Fig. 15 Rear Fog Lamp
1 ± REAR FOG LAMP
2 ± REAR FOG LAMP SOCKET
Fig. 16 Rear Fog Lamps
1 ± REAR FOG LAMPS
2 ± LAMP RETAINING SCREWS
Fig. 17 Side Repeater Lamp Retaining Tabs
1 ± RETAINING TABS
2 ± REPEATER LAMP
3 ± FENDER
Fig. 18 Side Repeater Lamp Socket
1 ± BULB SOCKET
2 ± REPEATER LAMP
PLLAMPS 8L - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install the side repeater lamp bulb in its
socket.
(2) Verify lamp operation.
(3) Install the lamp socket in the lamp housing
(Fig. 19).
(4) Install the lamp in the front fender. Install the
bottom mounting tab first then push lamp straight in
to secure in fender (Fig. 20).
(5) Install the front wheel splash shield retaining
pushpins and screws.
TAIL, STOP, BACK-UP AND TURN SIGNAL
LAMP BULBS
REMOVAL
(1) Open the trunklid and clear area by the rear
closure panel.
(2) Remove the pushpin and pull back the trunk
trim.
(3) Remove the (3) plastic retaining nuts and pull
the lamp assembly away from the vehicle (Fig. 21).
(4) Rotate the appropriate lamp socket and pull
straight out of the tail lamp assembly.
(5) Pull the lamp bulb straight from its socket.
Fig. 19 Side Repeater Lamp Socket
1 ± BULB SOCKET
2 ± REPEATER LAMP
Fig. 20 Side Repeater Lamp Retaining Tabs
1 ± RETAINING TABS
2 ± REPEATER LAMP
3 ± FENDER
Fig. 21 Tail Lamp Assembly
1 ± TAIL LAMP ELECTRICAL CONNECTOR
2 ± TAIL LAMP RETAINING NUTS
8L - 10 LAMPSPL
REMOVAL AND INSTALLATION (Continued)