battery DODGE NEON 2000 Service Manual PDF

REMOVAL AND INSTALLATION
HORN
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 5).
(2) Remove the windshield washer reservoir. Refer
to Group 8K Windshield Washer and Wipers, Washer
Reservoir Removal and Installation.
(3) Disconnect the harness connector.
(4) Remove the one screw holding the horn assem-
bly to vehicle (Fig. 6).
NOTE: The screw holding the horn assembly is a
captive screw and will remain as part of the assem-
bly.
INSTALLATION
For installation, reverse the above procedures.
HORN RELAY
REMOVAL
(1) Remove the Power Distribution Center cover
and locate the horn relay (Fig. 7).
(2) Remove the horn relay.
INSTALLATION
For installation, reverse the above procedures.
Fig. 5 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
Fig. 6 Horn Remove/Install
Fig. 7 Power Distribution Center (PDC)
8G - 4 HORNSPL

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)

SPEED CONTROL SERVO-PCM OUTPUT
DESCRIPTION
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
The PCM controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo's by the PCM
through the brake switch. The PCM controls the
ground path for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted,
the solenoid dumps vacuum in the servo. This pro-
vides a safety backup to the vent and vacuum sole-
noids.
The vacuum and vent solenoids must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo solenoid, the solenoid allows vacuum
to enter the servo and pull open the throttle plate
using the cable. When the PCM breaks the ground,
the solenoid closes and no more vacuum is allowed to
enter the servo. The PCM also operates the vent sole-
noid via ground. The vent solenoid opens and closes a
passage to bleed or hold vacuum in the servo as
required.
The PCM duty cycles the vacuum and vent sole-
noids to maintain the set speed, or to accelerate and
decelerate the vehicle. To increase throttle opening,
the PCM grounds the vacuum and vent solenoids. To
decrease throttle opening, the PCM removes the
grounds from the vacuum and vent solenoids. When
the brake is released, if vehicle speed exceeds 25
mph to resume, 30 mph to set, and the RES/ACCEL
switch has been depressed, ground for the vent and
vacuum circuits is restored.
SPEED CONTROL SWITCHESÐPCM INPUT
Description
There are two separate switch pods that operate
the speed control system. The steering-wheel-
mounted switches use multiplexed circuits to provide
inputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer tothe owner's manual for more information on speed
control switch functions and setting procedures.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
Operation
When speed control is selected by depressing the
ON, OFF switch, the PCM allows a set speed to be
stored in RAM for speed control. To store a set speed,
depress the SET switch while the vehicle is moving
at a speed between 25 and 85 mph. In order for the
speed control to engage, the brakes cannot be
applied, nor can the gear selector be indicating the
transmission is in Park or Neutral.
Once the speed control has been disengaged,
depressing the ACCEL switch restores the vehicle to
the target speed that was stored in the PCM's RAM.
NOTE: Depressing the OFF switch will erase the
set speed stored in the PCM's RAM.
If, while the speed control is engaged, the driver
wishes to increase vehicle speed, the PCM is pro-
grammed for an acceleration feature. With the
ACCEL switch held closed, the vehicle accelerates
slowly to the desired speed. The new target speed is
stored in the RAM when the ACCEL switch is
released. The PCM also has a ªtap-upº feature in
which vehicle speed increases at a rate of approxi-
mately 2 mph for each momentary switch activation
of the ACCEL switch.
The PCM also provides a means to decelerate with-
out disengaging speed control. To decelerate from an
existing recorded target speed, depress and hold the
COAST switch until the desired speed is reached.
Then release the switch. The ON, OFF switch oper-
ates two components: the PCM's ON, OFF input, and
the battery voltage to the brake switch, which powers
the speed control servo.
Multiplexing
The PCM sends out 5 volts through a fixed resistor
and monitors the voltage change between the fixed
resistor and the switches. If none of the switches are
depressed, the PCM will measure 5 volts at the sen-
sor point (open circuit). If a switch with no resistor is
closed, the PCM will measure 0 volts (grounded cir-
cuit). Now, if a resistor is added to a switch, then the
PCM will measure some voltage proportional to the
size of the resistor. By adding a different resistor to
each switch, the PCM will see a different voltage
depending on which switch is pushed.
8H - 2 VEHICLE SPEED CONTROL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

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)

To test the switch, first disconnect the negative
battery cable, then remove the upper and lower col-
umn shrouds to gain access to the switch connector.
Remove switch connector. Using an ohmmeter, testfor continuity (no resistance) between the terminals
of the switch as shown in the Multi-Function Switch
Continuity Test Chart for diagnosis. Refer to (Fig. 3),
(Fig. 4), and (Fig. 5) for connector terminal locations.
MULTI-FUNCTION SWITCH CONTINUITY TEST
SWITCH POSITION MODE CONTINUITY BETWEEN
TURN SIGNAL IN NEUTRAL
HAZARD WARNING SWITCH OFFNEUTRAL B-1 AND B-4
B-1 AND B-5
TURN SIGNAL ON
HAZARD WARNING SWITCH OFFLEFT TURN A-2 AND B-2
A-2 AND B-4
B-1 AND B-5
RIGHT TURN A-2 AND B-5
A-2 AND B-6
B-1 AND B-4
TURN SIGNAL IN NEUTRAL
HAZARD WARNING SWITCH ONNEUTRAL A-2 AND B-2
A-2 AND B-4
A-2 AND B-5
A-2 AND B-6
A-3 AND A-5
A-3 AND B-7
HEADLAMP BEAM ON PARK B-9 AND B-20
LOW B-16 AND B-18
B-16 AND B-19
HIGH B-17 AND B-18
B-17 AND B-19
OPTICAL HORN ON B-17 AND B-18
B-17 AND B-19
FRONT FOG ON B-13 AND B-14
INSTRUMENT PANEL DIMMER DETENT 6 DIMMEST B-7 AND B-8 3181 OHMS
5 B-7 AND B-8 1851 OHMS
4 B-7 AND B-8 1202 OHMS
3 B-7 AND B-8 598 OHMS
2 BRIGHTEST B-7 AND B-8 250 OHMS
1 PARADE B-7 AND B-8 100 OHMS
0 DOME LAMP ON B-7 AND B-8 LESS THAN 1 OHM
WIPER OFF PIN C-1 AND C-6
LOW/ MIST PIN C-4 AND C-6
HIGH PIN C-4 AND C-5
WASH PIN C-4 AND C-3
INTERMITTENT CANNOT BE CHECKED
8J - 4 TURN SIGNAL and HAZARD WARNING SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
COMBINATION FLASHER
The flasher is mounted to the back side of the
multi-function switch (Fig. 2). To gain access the
upper steering column shroud must be removed.
Refer to Group 8E Instrument Panel Systems, Steer-
ing Column Shroud Removal and Installation. The
flasher can be removed by pulling it toward the
instrument cluster (forward). The flasher is serviced
separately from the multi-function switch.
MULTI-FUNCTION SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Remove both upper and lower steering column
shrouds. Refer to Group 8E Instrument Panel Sys-
tems, Steering Column Shroud Removal and Instal-
lation.
Fig. 3 Combination Flasher Connector (A)
Fig. 4 Multi-Function Switch Connector (B)
Fig. 5 Windshield Wiper/Washer Switch Connector
(C)
Fig. 6 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
PLTURN SIGNAL and HAZARD WARNING SYSTEMS 8J - 5
DIAGNOSIS AND TESTING (Continued)

DIAGNOSIS AND TESTING
WINDSHIELD WIPER CONDITIONS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M, PASSIVE
RESTRAINT SYSTEMS FOR STEERING WHEEL
REMOVAL AND INSTALLATION.
The following is a list of general wiper motor sys-
tem problems, the tests that are to be performed to
locate the faulty part, and the corrective action to be
taken.
Whatever the problem, disconnect motor wire har-
ness and clean the terminals, then connect motor
wire harness and test.
Refer to Group 8W Wiring Diagrams for circuit
information and connector call-outs.
MOTOR WILL NOT OPERATE IN SOME OR ALL
SWITCH POSITIONS
(1) Check fuse 1, in the fuse block (Fig. 1).
(a) If fuse is OK, go to Step 2.
(b) If fuse is defective, replace and check motor
operation in all switch positions.
(c) If motor is still inoperative and the fuse does
not blow, go to Step 2.
(d) If replacement fuse blows, go to Step 6.
(2) Disconnect motor harness connector.(3) Check motor low speed. Using two jumper
wires, connect one jumper wire between the battery
positive terminal and terminal 4 of the motor connec-
tor. Connect the other jumper wire to the battery
negative terminal and the motor ground strap (Fig.
2). Check motor high speed, connect the positive
jumper wire to terminal 5 of the motor connector.
Connect the negative jumper wire to the motor
ground strap.
(a) If motor does not run in high or low speed go
to Step 4.
(b) If motor does run, go to Step 5.
(4) Using an ohmmeter, check for good ground at
the motor ground strap. If OK, replace motor. If not
repair the ground circuit as necessary.
(5) Check terminal 2 of wiper switch connector for
continuity to ground. If OK, go to Step 6. If not OK,
repair the ground circuit as necessary.
(6) Using a voltmeter, with wiper switch con-
nected, connect negative lead to motor ground strap.
Connect the positive lead to terminal 4 of the wiper
switch connector (Fig. 3).
Fig. 1 Fuse Block
1 ± FUSE 1 WIPER
Fig. 2 Windshield Wiper Motor Connector
Fig. 3 Windshield Wiper Switch Connector
8K - 2 WINDSHIELD WIPER and WASHER SYSTEMSPL

(a) If no voltage, repair wiring as necessary. If
OK, go to Step b.
(b) Check wiper switch low speed. Connect volt-
meter positive lead to terminal 6 of the wiper
switch connector. Move wiper stalk to LOW posi-
tion. If no voltage, replace switch.
(c) Check wiper switch high speed, connect volt-
meter positive lead to terminal 5 of the wiper
switch connector. Move wiper stalk to HIGH posi-
tion. If no voltage, replace switch.
(7) Disconnect motor connector and replace fuse 1
in fuse block.
(a) If fuse does not blow, replace motor.
(b) If fuse blows, disconnect wiper switch and
replace fuse.
(c) If fuse does not blow, replace switch.
(d) If fuse blows, repair wiring as necessary.
MOTOR OPERATES SLOWLY AT ALL SPEEDS
(1) Remove wiper arms and cowl screen. Discon-
nect motor linkage from motor. Connect an ammeter
between battery positive terminal and terminal 4 of
the motor connector. Turn wiper motor on and check
ampere reading.
If motor runs and ammeter reading is more than 6
amps, go to Step 2. If less than 6 amps, go to Step 3.
When replacing drive link nut tighten to 11 to 12
N´m (98 to 106 in. lbs.) torque.
(2) Using an ohmmeter, check the high and low
circuits for a short to ground. Refer to Group 8W,
Wiring Diagrams.
(3) Check to see if wiper linkage or pivots are
binding or caught.
WIPERS RUN AT HIGH SPEED WITH SWITCH IN
LOW SPEED POSITION OR WIPERS RUN AT LOW
SPEED WITH SWITCH IN HIGH SPEED POSITION.
(1) Check for crossed wires in the motor pigtail
wire connector. Refer to Group 8W, Wiring Diagrams.
(2) Check for crossed wires in harness connector
from wiper switch to motor.
(3) If OK, replace wiper switch.
WIPERS WILL OPERATE CONTINUOUSLY WITH
THE SWITCH IN THE INTERMITTENT POSITION -
WHEN WIPER SWITCH IS TURNED OFF, WIPERS
STOP WHEREVER THEY ARE WITHOUT
RETURNING TO PARK POSITION.
(1) Check at motor ground strap for a good ground.
(2) Turn ignition switch OFF. Disconnect the wiper
switch harness connector. Using an ohmmeter with
the motor in the park position, check for continuity
between terminal 2 of the wiper switch harness con-
nector (Fig. 4) and the ground strap. If continuity,
replace wiper switch. If no continuity, repair wiring
as necessary.
WIPERS DO NOT OPERATE WHEN WASHER
MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS
DO OPERATE IN INTERMITTENT POSITION.
Check for a good ground at motor ground strap and
at wiper switch terminal 2. If OK, replace wiper
switch. If not OK, repair wiring as necessary.
WINDSHIELD WIPER MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
STEERING WHEEL OR COLUMN REMOVAL PROCE-
DURES.
Whenever a wiper motor malfunction occurs, verify
that the wire harness is properly connected, then
start normal diagnosis and repair procedures. Refer
to Wiper Motor Test table.
Fig. 4 Windshield Wiper Switch Harness Connector
PLWINDSHIELD WIPER and WASHER SYSTEMS 8K - 3
DIAGNOSIS AND TESTING (Continued)

WIPER MOTOR TEST
CONDITION POSSIBLE CAUSES CORRECTION
WIPER BLADES DO NOT
PARK PROPERLY.(1) WIPER ARMS IMPROPERLY
PARKED.
(2) WIPER ARMS ARE LOOSE ON
PIVOT SHAFT.
(3) MOTOR CRANK LOOSE AT
OUTPUT SHAFT.(1) REMOVE WIPER ARMS AND
REPARK. REFER TO WIPER ARM
REMOVAL AND INSTALLATION.
(2) REMOVE WIPER ARM AND
REPARK. REFER TO WIPER ARM
REMOVAL AND INSTALLATION.
(3) REMOVE WIPER ARM, RUN WIPER
MOTOR TO PARK POSITION AND
REMOVE THE MODULE. WITHOUT
ROTATING THE MOTOR OUTPUT
SHAFT, REMOVE THE CRANK AND
CLEAN ANY FOREIGN MATTER FROM
THE MOTOR SHAFT. INSTALL THE
MOTOR CRANK IN ITS ORIGINAL
POSITION.
MOTOR STOPS IN ANY
POSITION WHEN THE
SWITCH IS TURNED
OFF.(1) OPEN PARK CIRCUIT. (1) CHECK PARK SWITCH BY
DISCONNECTING THE WIRE
CONNECTOR AND APPLY BATTERY
VOLTAGE TO PIN 4. PLACE A JUMPER
WIRE FROM PIN 2 TO PIN 3 AND THEN
TO AN EXTERNAL GROUND. REPLACE
MOTOR IF IT DOES NOT PARK.
MOTOR WILL NOT STOP
WHEN THE SWITCH IS
TURNED OFF.(1) FAULTY SWITCH.
(2) LOCK OF DYNAMIC BRAKE
ON WET GLASS.(1) CHECK SWITCH IN LOW, HIGH AND
INTERMITTENT POSITION.
(2) ENSURE PARK SWITCH HAS
CLEAN GROUND.
WIPER BLADES SLAP
AGAINST COWL
SCREEN OR WINDOW
MOLDINGS.(1) WIPER ARMS ARE PARKED
INCORRECTLY.(1) PARK WIPER ARMS. REFER TO
WIPER ARM ADJUSTMENT.
BLADES CHATTER. (1) FOREIGN SUBSTANCE SUCH
AS POLISH ON GLASS OR
BLADES.
(2) ARMS TWISTED, BLADE AT
WRONG ANGLE ON GLASS.
(3) BLADE STRUCTURE BENT.
(4) BLADE ELEMENT HAS
PERMANENT SET.(1) CLEAN GLASS AND BLADE
ELEMENT WITH NON-ABRASIVE
CLEANER.
(2) REPLACE ARM.
(3) REPLACE BLADE.
(4) REPLACE BLADE ELEMENT.
WIPER KNOCK AT
REVERSAL.(1) LINKAGE BUSHINGS WORN.
(2) ARMATURE ENDPLAY IN
MOTOR.(1) REPLACE WORN LINK. REFER TO
WIPER LINKAGE REMOVAL AND
INSTALLATION.
(2) REPLACE WIPER MOTOR. REFER
TO WIPER MOTOR REMOVAL AND
INSTALLATION.
WIPER MOTOR WILL
NOT RUN.(1) BLOWN FUSE.
(2) NEW FUSE BLOWS.
(3) NEW FUSE BLOWS.
(4) NO VOLTAGE AT MOTOR.
(5) POOR GROUND.(1) REPLACE FUSE, AND RUN
SYSTEM.
(2) CHECK FOR SHORT IN WIRING OR
SWITCH.
(3) REPLACE FUSE, REMOVE MOTOR
CONNECTOR, TURN SWITCH ON,
FUSE DOES NOT BLOW, REPLACE
MOTOR.
(4) CHECK SWITCH AND WIRING
HARNESS. REFER TO GROUP 8W,
WIRING DIAGRAMS.
(5) REPAIR GROUND WIRE
CONNECTION AS NECESSARY.
8K - 4 WINDSHIELD WIPER and WASHER SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)