hose DODGE NEON 2000 Service Manual PDF

On most vehicles another resistor has been added
to the at rest circuit causing the PCM to never see 5
volts. This was done for diagnostic purposes. If the
switch circuit should open (bad connection) then the
PCM will see the 5 volts and know the circuit is bad.
The PCM will then set an open circuit fault.
STOP LAMP SWITCH
DESCRIPTION
The switch is mounted on the brake pedal mount-
ing bracket under the instrument panel.
OPERATION
Vehicles equipped with the speed control option use
a dual function stop lamp switch. The PCM monitors
the state of the dual function stop lamp switch. Refer
to the Brake section for more information on stop
lamp switch service and adjustment procedures.
The brake switch is equipped with three sets of
contacts, one normally open and the other two nor-
mally closed (brakes disengaged). The PCM sends a
12 volt signal to one of the normally closed contacts
in the brake switch, which is connected to a ground.
With the contacts closed, the 12 volt signal is pulled
to ground causing the signal to go low. The low volt-
age signal, monitored by the PCM, indicates that the
brakes are not applied. When the brakes are applied,
the contacts open, causing the PCM's output voltage
to go high, disengaging the speed control also
grounding the dump solenoid.
The second set of normally closed contacts is sup-
plied battery voltage any time speed control is
selected. From the brake switch, current is routed to
the speed control servo solenoids. The speed control
solenoids (vacuum, vent and dump) are provided this
current any time the speed control is ON and the
brakes are disengaged. When the driver applies the
brakes, the contacts open and current is interrupted
to the solenoids. The normally open contacts are fed
battery voltage. When the brakes are applied, battery
voltage is supplied to the stop lamps.
SERVO CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
VACUUM RESERVOIR
OPERATION
The reservoir stores engine vacuum in the reser-
voir. When engine vacuum drops, as in climbing a
grade while driving, the reservoir supplies the vac-
uum needed to maintain proper speed control opera-
tion. The vacuum reservoir cannot be repaired and
must be replaced if faulty.
VEHICLE SPEED SENSOR
The Vehicle Speed Sensor (VSS) is a pulse genera-
tor mounted to an adapter near the transmission out-
put shaft. The sensor is driven through the adapter
by a speedometer pinion gear. The VSS pulse signal
to the speedometer/odometer is monitored by the
PCM speed control circuitry to determine vehicle
speed and to maintain speed control set speed.
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
REMOVAL
(1) Disconnect electrical connector from servo (Fig.
2).
(2) Disconnect vacuum hose from servo
(3) Remove 2 nuts retaining cable to servo.
(4) Remove retaining clip pin holding cable to
servo.
Fig. 2 Speed Control Servo
PLVEHICLE SPEED CONTROL SYSTEM 8H - 3
DESCRIPTION AND OPERATION (Continued)

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)

VACUUM RESERVOIR
REMOVAL
(1) Raise and support vehicle.
(2) Remove screws on top of vacuum reservoir.
(3) Remove vacuum hose.
(4) Remove vacuum reservoir (Fig. 5).
INSTALLATION
(1) Install vacuum reservoir, install screws and
tighten to 5 N.m (44 in. lbs.).
(2) Install vacuum hose.
(3) Lower vehicle.
Fig. 5 Vacuum Reservoir
PLVEHICLE SPEED CONTROL SYSTEM 8H - 5
REMOVAL AND INSTALLATION (Continued)

WINDSHIELD WASHER SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WINDSHIELD WASHER NOZZLE(S)............8
WINDSHIELD WASHER SYSTEM.............8
DIAGNOSIS AND TESTING
WINDSHIELD WASHER SYSTEM.............9REMOVAL AND INSTALLATION
WINDSHIELD WASHER HOSE................9
WINDSHIELD WASHER NOZZLES.............9
WINDSHIELD WASHER RESERVOIR..........10
WINDSHIELD WASHER PUMP...............10
DESCRIPTION AND OPERATION
WINDSHIELD WASHER NOZZLE(S)
This model is equipped with two hood mounted
washer nozzles. Each nozzle emits two streams into the
wiper pattern (Fig. 1). If the nozzle performance is
unsatisfactory they can be adjusted. To adjust insert a
pin into the nozzle ball and move to proper pattern (Fig.
2). The right and left nozzles are identical.
WINDSHIELD WASHER SYSTEM
All models are equipped with electrically operated
windshield washer pumps. The wash function can be
accessed in the OFF position of the wiper control
switch. Holding the wash button depressed when the
switch is in the OFF position will operate the wipers
and washer motor pump continuously until the
washer button is released. Releasing the button will
stop the washer pump but the wipers will complete
the current wipe cycle. Followed by an average of two
more wipe cycles (61) before the wipers park and the
module turns off.
The electric pump assembly is mounted directly to
the reservoir. A permanently lubricated motor is cou-
pled to a rotor type pump. Fluid, gravity fed from the
reservoir, is forced by the pump through rubber hoses
to the hood mounted nozzles which direct the fluid
streams to the windshield.
The pump and reservoir are serviced as separate
assemblies (Fig. 3).
Fig. 1 Windshield Washer Nozzle - Typical
1 ± HOOD
2 ± ADJUST WITH A PIN
3 ± NOZZLE
4 ± FWD
Fig. 2 Windshield Washer Pattern - Typical
1 ± NOZZLE AIR TARGET
Fig. 3 Windshield Washer Reservoir
1 ± WINDSHIELD WASHER PUMP
2 ± SPEED CONTROL VACUUM RESERVOIR
3 ± WINDSHIELD WASHER HOSE
8K - 8 WINDSHIELD WIPER and WASHER SYSTEMSPL

DIAGNOSIS AND TESTING
WINDSHIELD WASHER SYSTEM
Whenever a windshield washer malfunction occurs,
first verify that the windshield washer wire harnessis properly connected to all connectors before starting
normal diagnosis and repair procedures. Refer to
Windshield Washer System Test table.
WINDSHIELD WASHER SYSTEM TEST
CONDITION POSSIBLE CAUSE CORRECTION
PUMP RUNS NO FLUID
FLOWING.1. NO FLUID IN THE
RESERVOIR.
2. NOZZLE PLUGGED
OR FROZEN.
3. BROKEN, LOOSE OR
PINCHED HOSE.
4. FAULTY PUMP.1. FILL RESERVOIR.
2. THAW AND CHECK FLOW IF BLOCKED
3. CHECK FLOW THROUGH HOSE CONNECTIONS.
4. APPLY BATTERY VOLTAGE TO MOTOR
TERMINALS, REPLACE IF PUMP DOES NOT RUN.
SYSTEM OPERATES
INTERMITTENTLY.1. LOOSE WIRE
CONNECTION.
2. FAULTY SWITCH.1. CHECK WIRE CONNECTIONS.
2. DISCONNECT WIRE HARNESS USE
VOLTMETER TO CHECK SWITCH.
SYSTEM OUTPUT IS
LOW.1. PINCHED HOSE.
2. HOSE BLOCKED.1. CHECK FLOW THROUGH HOSE CONNECTION.
2. DISCONNECT HOSE AT NOZZLE AND Y
CONNECTOR CHECK FOR FLOW. REPLACE ASS
NECESSARY.
REMOVAL AND INSTALLATION
WINDSHIELD WASHER HOSE
REMOVAL
For damaged or plugged windshield washer hose,
remove the effected piece of hose and replace routing
hose the same way as removed (Fig. 4).
INSTALLATION
For installation, reverse the above procedures.
WINDSHIELD WASHER NOZZLES
REMOVAL
(1) Open hood.
(2) Disconnect the windshield washer hose from
the underside of the washer nozzle.
(3) Using a plastic body filler spreader or equiva-
lent (credit card), gently place it underneath the
front of the washer nozzle. Be careful not to damage
the hood seal underneath the nozzle.
(4) Rock the nozzle back and forth slightly to
release it from the hood panel.
INSTALLATION
(1) For installation, reverse the above procedures.
(2) After connecting hose, check for proper system
function and to assure leak free connections by actu-
ating the washer system switch from inside of vehi-
cle.
Fig. 4 Windshield Washer Hose
PLWINDSHIELD WIPER and WASHER SYSTEMS 8K - 9

WINDSHIELD WASHER RESERVOIR
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the wire connector from the reser-
voir pump (Fig. 5).
(3) Disconnect the washer hose at the pump and
drain the reservoir.
(4) Disconnect the vacuum connector to the speed
control vacuum reservoir.
(5) Remove fasteners from reservoir.
(6) Remove the reservoir through fender opening.
If replacing reservoir, the windshield washer pump
and the speed control vacuum reservoir must be
transferred to the new washer reservoir.
(7) Remove two fasteners retaining speed control
vacuum reservoir.
(8) Remove to the windshield washer pump from
the reservoir. Refer to Windshield Washer Pump
Removal and Installation in this section.
INSTALLATION
For installation, reverse the above procedures.
Tighten the reservoir screws to 2.2 to 3.3 N´m (20 to
29 in. lbs.) torque.
WINDSHIELD WASHER PUMP
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the wire connector from the reser-
voir pump.
(3) Disconnect the washer hose at the pump and
drain the reservoir.
(4) Gently pry pump away from reservoir and out
of grommet. Care must be taken not to puncture res-
ervoir (Fig. 6).
(5) Remover rubber grommet from reservoir. If
replacing the pump, discard the old washer pump
grommet. If replacing the reservoir only, reuse the
old washer pump grommet.
INSTALLATION
For installation, reverse the above procedures.
Make sure to use new grommet when installing new
washer pump.
Fig. 5 Windshield Washer Reservoir Remove/Install
Fig. 6 Windshield Washer Pump Remove/Install
1 ± WASHER PUMP
2 ± RUBBER GROMMET
8K - 10 WINDSHIELD WIPER and WASHER SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

POWER LOCK SYSTEMS
TABLE OF CONTENTS
page page
POWER DOOR LOCKS...................... 1REMOTE KEYLESS ENTRY (RKE).............. 4
POWER DOOR LOCKS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION..........................1
POWER DOOR LOCKS.....................2
CHILD PROTECTION LOCKS................2
DOOR LOCK INHIBIT.......................2
DIAGNOSIS AND TESTING
DOOR LOCK MOTOR......................2
DOOR LOCK SWITCH......................2SERVICE PROCEDURES
DOUBLE ACTIVATION UNLOCK...............3
ROLLING DOOR LOCKS....................3
REMOVAL AND INSTALLATION
DOOR LOCK MOTOR/LATCH.................3
DOOR LOCK SWITCH......................3
REMOTE KEYLESS ENTRY (RKE) MODULE.....3
DESCRIPTION AND OPERATION
INTRODUCTION
All doors can be locked or unlocked electrically by
operating the switch on either front door panel.
When the door lock switch is activated the Remote
Keyless Entry Module provides power to the door
lock motors through relays internal to the module.
The Remote Keyless Entry (RKE) Module also con-
trols the Vehicle Theft Security System (VTSS).
All doors can be locked or unlocked mechanically
and independently with their respective locking
knobs. The front doors can also be unlocked by actu-
ation of the inside remote door handle.
The RKE Module has three modes of operation
including customer usage mode, dealer lot storage
mode, and shipping mode. The customer usage mode
provides full functionality of the module and is the
mode in which the RKE module should be operating
when used by the customer. Dealer lot storage mode
and shipping modes are reduced power modes meant
to extend vehicle battery life during shipping and
storage in the dealer lot. Dealer lot storage mode pro-
vides limited VTSS and power door lock functions,
but disables the Remote Keyless Entry (RKE) func-
tions. This mode is intended to be used when the
vehicle is on the dealer lot to provide VTSS coverageof the vehicle while minimizing battery drain. Ship-
ping mode disables all normal functions (i.e. power
door locks, RKE, and VTSS) of the module, and is
intended to be used when the vehicle is shipped from
the assembly plant.
NOTE: The dealer must remove the module from
ªShip Modeº and place the RKE Module into either
the ªDealer Lotº storage or ªCustomer Usageº
modes of operation after receiving the vehicle from
the assembly plant. Refer to Group 8Q-Vehicle
Theft/Security Systems, Switching Operating
Modes/Configuring a New Module under Service
Procedures.
CENTRAL LOCKING/UNLOCKING
The door locks can be locked or unlocked electri-
cally via the exterior door key cylinders to provide
the central locking/unlocking feature. The central
locking/unlocking feature incorporates a customer
programmable ``Double activation unlockº feature
which operates in the following manner: When
enabled, the first turn of the key cylinder to the
UNLOCK position (toward the front of the vehicle)
will mechanically unlock the door whose key cylinder
is being turned. A second turn of the key cylinder to
the UNLOCK position (within five seconds of the
PLPOWER LOCK SYSTEMS 8P - 1

SECTION IDENTIFICATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
SYMBOLS
International symbols are used throughout the wir-
ing diagrams. These symbols are consistent with
those being used around the world.
GROUP TOPIC
8W-01 thru
8W-09General Information and Diagram
Overview
8W-10 thru
8W-19Main Sources of Power and Vehicle
Grounding
8W-20 thru
8W-29Starting and Charging
8W-30 thru
8W-39Powertrain/Drivetrain Systems
8W-40 thru
8W-49Body Electrical items and A/C
8W-50 thru
8W-59Exterior Lighting, Wipers, and Trailer
To w
8W-60 thru
8W-69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations (including
grounds)
8W-95 Splice Locations
PL8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)

make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (makeup air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and CCV hose. Proceed to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of theengine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil galley cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurized the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, refer to Crank-
shaft Oil SealÐRear for proper replacement proce-
dures.
9 - 10 ENGINEPL
DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. Refer to
Group 8B, Starting.
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
Refer to Group 8D, Ignition System.
5. Incorrect spark plug gap. 5. Set gap. Refer to Group 8D,
Ignition System.
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s). 4. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Install new parts, as necessary.
9. Faulty coil(s). 9. Test and replace as necessary.
Refer to Group 8D, Ignition System.
PLENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)