tire DODGE NEON 2000 Service Manual PDF

HEADLAMP ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT....................4
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION........4ADJUSTMENTS
HEADLAMP ADJUSTMENT USING
ALIGNMENT SCREEN....................4
FOG LAMP ALIGNMENT....................6
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT
Headlamps and Fog Lamps should be aligned
using the screen method which is provided in this
section.The preferred headlamp alignment set-
ting is 0 for the left/right adjustment and 0 for
the up/down adjustment.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens.
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall
(Fig. 1).(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) A small dot is molded into each headlamp lens
signifying the center of the headlamp. Measure the
distance from the center of the headlamp to the floor.
Transfer measurement to the alignment screen (with
tape). Use this line for up/down adjustment refer-
ence.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
The PL headlamp low beam pattern has a distinct
horizontal cutoff line which is used to visually align
the headlamps. A properly aimed headlamp will have
the horizontal cutoff line of the low beam pattern
centered on the low beam pattern centered on the
horizontal center of headlamp line. The side to side
left edge of the low beam hot spot should be located
75 mm (3 inches) to the left of the headlamp center
line (Fig. 1). The high beams on a vehicle with aero
headlamps cannot be aligned. The high beam pattern
should be correct when the low beams are aligned
properly.
To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern.
8L - 4 LAMPSPL

HEADLAMP ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT....................2
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION........2ADJUSTMENTS
HEADLAMP ADJUSTMENT USING
ALIGNMENT SCREEN....................2
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method
provided in this section. This method will require the
vehicle to be parked on a flat, level surface with a
minimum of 15 meters of working room in front of a
flat, level perpendicular wall or aiming.
Each headlamp has a focal point circle molded on
the lens directly in front of each headlamp bulb.
These focal point circles are used to set up lines on a
wall, or aiming board for visually aiming the head-
lamps.
The driving (high) beam location does not require
adjustment. It will be correct when the passing (low)
beam headlamps are aimed correctly.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify that the headlamp leveling switch is in
the ª0º position.
(4) Verify proper tire inflation.
(5) Clean the headlamp lenses.
(6) Verify that the luggage area is not heavily
loaded.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position the vehicle on a level surface 10
meters in front of a level, flat wall or aiming board.
(2) Tape a vertical line on the wall extending 1
meter up from the floor, making sure this line is even
with the centerline of the vehicle (Fig. 1).
(3) Measure the cross-car distance between the
two headlamp focal point circles (1174mm). Transfer
half of this distance (587mm) to the left of the vehicle
centerline and tape another vertical line up from the
floor 1 meter (Fig. 1). Repeat for the right side of the
centerline.
(4) Measure the distance from the floor to the focal
point circle on the headlamp lens (635mm, but may
vary due to variations in tire size and vehicle suspen-
sion height). Transfer this measurement to the wall
and tape a horizontal line extending approximately 1
meter beyond each vertical focal point line (Fig. 1).
(5) Use these lines for left and right adjustment
reference.
HEADLAMP ADJUSTMENT
Horizontal Adjustment
The horizontal position of the passing (low) beam
pattern is adjusted by turning the T-15 Torx screw.
Located through the slot in the upper-crossmember
between the two attaching straps of the headlamp.
Vertical Adjustment
The vertical position of the passing (low) beam pat-
tern is adjusted by turning the Phillips screw on top
of the headlamp leveling motor. Located between the
headlamp housing and the upper-crossmember, just
inboard of the fender.
Adjust the passing (low) beam headlamp pat-
terns to the locations shown in the chart pro-
vided (Fig. 1).
8L - 2 LAMPSPL

INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the three module
retaining nuts to 22 to 34 N´m (200 to 300 in. lbs.)
torque. Do not connect battery negative cable. Refer
to Diagnosis and Testing for Airbag System Test pro-
cedures.
DEPLOYED MODULE
REMOVAL
When removing a deployed module, rubber gloves,
eye protection, and a long-sleeved shirt should be
worn, as there may be deposits on the surface which
could irritate the skin and eyes.
(1) Roll/fold airbag towards instrument panel.
(2) Close door over folded airbag and tape door
closed.
(3) Disconnect and isolate the battery negative
cable (Fig. 4).
(4) Remove instrument panel top cover. Refer to
Group 8E Instrument Panel Systems, Instrument
Panel Top Cover Removal and Installation.
(5) Remove three screws to glove box door and
remove door from instrument panel.
(6) Remove three passenger airbag cover screws
attaching cover to top of instrument panel (Fig. 9).
(7) Remove two passenger airbag cover screws
attaching cover to front lower instrument panel.
(8) Remove three module attaching nuts from the
support structure.
(9) Lift module up until the wire connector is visi-
ble and disconnect the 4-way wire connector from
module. Unlock the red locking tab and compress
lock to release the connector (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the module nuts to
22 to 34 N´m (200 to 300 in. lbs.) torque. Do not con-
nect battery negative cable. Refer to Diagnosis and
Testing for Airbag System Test procedures.
STEERING WHEEL
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE BEFORE
BEGINNING ANY AIRBAG SYSTEM COMPONENT
REMOVAL OR INSTALLATION PROCEDURE. THIS
WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO
DISCONNECT BATTERY COULD RESULT IN ACCI-DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
REMOVAL
(1) Adjust the steering wheel so that the tires are
in the straight ahead position. Then:
(a) Rotate the steering wheel half turn (180
degrees) to the right (clockwise).
(b) Lock column with the ignition cylinder lock.
(2) Disconnect and isolate the battery negative
cable (Fig. 4).
(3) Remove the speed control switches and discon-
nect the wire connectors or covers (Fig. 11).
(4) Remove the Driver Airbag Module attaching
bolts from the back of steering wheel.
(5) Lift module and disconnect the airbag and horn
wire connectors.
(6) Remove steering wheel retaining nut.
(7) Remove the steering wheel with a steering
wheel puller (Fig. 12). While removing the steering
wheel take care to feed the wires gently through the
holes in the steering wheel.
INSTALLATION
(1) Confirm that:
(a) The steering wheel position is a half turn
(180 degrees) to the right (clockwise).
(b) The column is locked with the ignition cylin-
der lock.
(c) Check that the turn signal stalk is in the
neutral position.
(2) Install the steering wheel ensuring the flats on
hub align with the clockspring. Pull the horn lead,
airbag and speed control leads through the larger
Fig. 11 Steering Wheel Remove/Install
8M - 8 PASSIVE RESTRAINT SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

The fusible link, fuses and relays are available for
service replacement. The PDC unit cannot be
repaired and is only serviced as a unit with the
engine compartment wire harness. If the PDC is
faulty or damaged, the engine compartment wire har-
ness assembly must be replaced.
FUSE BLOCK
An electrical Fuse Block is located in the left end
of the instrument panel (Fig. 2). It serves to simplify
and centralize numerous electrical components, as
well as to distribute electrical current to many of the
accessory systems in the vehicle.
The Fuse Block is positioned on a mounting
bracket up and under the left instrument panel. It is
secured by two screws. The fuse block is concealed
behind the left instrument panel end cap. The left
end cap is a snap-fit access cover that conceals the
fuse block fuses. A fuse layout placard is on the back
of the end cap to ensure proper fuse identification.
The fuse block houses blade-type fuses and auto-
matic resetting circuit breakers (Fig. 3). Internal con-
nection of all the fuse block circuits is accomplished
by an intricate network of hard wiring and bus bars.
Refer toJunction Blockin the Component Index of
Group 8W - Wiring Diagrams for complete circuit
diagrams.
The fuses and circuit breakers are available for
service replacement. The fuse block unit cannot be
repaired and is only serviced as an assembly. If any
circuit or the fuse block housing is faulty or dam-
aged, the entire fuse block and instrument panel
wire harness assembly must be replaced.
REMOVAL AND INSTALLATION
FUSE BLOCK
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
The Fuse Block is serviced with the instrument
panel wire harness. If service is required to the fuse
block, the entire instrument panel harness must be
replaced.
(1) The instrument panel must be removed from
the vehicle. Refer to Group 8E-Instrument Panel and
Systems for Instrument Panel Removal and Installa-
tion.
(2) With the instrument panel on the bench,
de-trim the instrument panel enough to gain access
to all screws and connectors to remove instrument
panel wire harness with fuse block.
INSTALLATION
For installation, reverse the above procedures.
Ensure that the wire terminals and connectors are in
good condition and connectors are properly installed.
POWER DISTRIBUTION CENTER (PDC)
The Power Distribution Center (PDC) is serviced
as a unit with the engine compartment wire harness.
If any internal circuit of the PDC or the PDC hous-
ing is faulty or damaged, the entire PDC and engine
compartment wire harness unit must be replaced.
Fig. 2 Fuse Block Location
Fig. 3 Fuse Block
1 ± CIRCUIT BREAKER 2
2 ± CIRCUIT BREAKER 1
8O - 2 POWER DISTRIBUTION SYSTEMSPL
DESCRIPTION AND OPERATION (Continued)

POWER MIRRORS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DIAGNOSIS AND TESTING
POWER FOLD AWAY MIRROR SWITCH TEST...1POWER FOLD AWAY MIRROR MOTOR........1
REMOVAL AND INSTALLATION
POWER FOLD-AWAY MIRROR SWITCH.......1
POWER FOLD-AWAY MIRROR...............2
GENERAL INFORMATION
INTRODUCTION
These vehicles may be equipped with Power Fold
Away Mirrors. The vehicle has an additional switch
in the switch pod that controls the folding function of
the mirror assembly (Fig. 1).
All vehicles are equipped with a Ignition-Off Draw
Fuse, and they are disconnected when the vehicles
are originally shipped from the factory. Disconnecting
this fuse will help prevent the battery from discharge
during storage. The fuse is located in Power Distri-
bution Center (PDC) refer to the cover for proper
location.
This fuse is included in the power mirror circuity
and should be checked if the mirrors are inoperative.
The vehicle mirror circuitry is powered from the
accessory feed circuit and protected by a 15 amp cir-
cuit breaker and power mirror relay. The relay pro-
vides for the switching of the mirror. The circuit
breaker and mirror relay are located in the inner
door panel wire harness.
DIAGNOSIS AND TESTING
POWER FOLD AWAY MIRROR SWITCH TEST
(1) Remove power mirror switch from the door
trim panel. Refer to the switch removal and installa-
tion procedure in this group.
(2) Using an ohmmeter, test for continuity between
the terminals of the switch as shown in the Power
Fold Away Mirror Switch Test (Fig. 2).
(3) If test results are not obtained as shown in
(Fig. 2), replace the switch.
Refer to Group 8W, Wiring Diagrams for a com-
plete schematic of the power mirror circuitry.
POWER FOLD AWAY MIRROR MOTOR
The power fold away mirror motor is incorporated
into the mirror assembly. If the motor proves to be
inoperative the entire mirror assembly must be
replaced. Refer to the mirror removal and installa-
tion procedure in this group for detailed instructions.
(1) Remove the power mirror switch from the door
trim panel. Refer to the removal and installation pro-
cedure in this group.
(2) Disconnect the mirror switch electrical connec-
tor.
(3) Using two jumper wires, one connected to a 12
volt source, and the other connected to a good body
ground. Refer to the Mirror Switch Circuits (Fig. 3)
and check for the appropriate mirror responses.
(4) If test results are not obtained as shown in
(Fig. 3), check for a open or shorted circuit, or replace
mirror / motor assembly as necessary.
Refer to Group 8W, Wiring Diagrams for a com-
plete wiring schematic of the power mirror circuitry.
REMOVAL AND INSTALLATION
POWER FOLD-AWAY MIRROR SWITCH
REMOVAL
(1) Disconnect the negative battery cable.
Fig. 1 Power Fold Away Mirror Switch
PLPOWER MIRRORS 8T - 1

TERMINOLOGY
This a list of terms with there definitions used in
the wiring diagrams.
Built-Up-Export....... Vehicles Built For Sale In
Markets Other Than North America
Except-Built-Up-Export . Vehicles Built For Sale In
North America
LHD ................Left Hand Drive Vehicles
RHD ...............Right Hand Drive Vehicles
ATX . . Automatic Transmission-Front Wheel Drive
MTX ....Manual Transmission-Front Wheel Drive
AT ....Automatic Transmission-Rear Wheel Drive
MT......Manual Transmission-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC............Dual Over Head Cam Engine
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located on theengine com-
partment harnessareC100series numbers.
²Connectors located on theinstrument panel
harnessareC200series numbers.
²Connectors located on thebody harnessare
C300series numbers.
²Jumper harness connectorsareC400series
numbers.
²Grounds and ground connectorsare identi-
fied with aªGºand follow the same series number-
ing as the in-line connector.
Component connectors are identified by the compo-
nent name instead of a number. Multiple connectors
on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-90 contains connector/ground location
illustrations. The illustrations contain the connector
name (or number)/ground number and component
identification. Connector/ground location charts in
Section 8W-90 reference the illustration number for
components and connectors.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the Dia-
gram pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
PL8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)

(2) Connect the other lead of the voltmeter to the
other side of the switch or component.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
SERVICE PROCEDURES
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gage be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1) (Fig. 7).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 7).
(6) Twist the wires together (example 3) (Fig. 7).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
Fig. 6 Testing for Voltage Drop
Fig. 7 Wire Repair
1 ± EXAMPLE 1
2 ± EXAMPLE 2
3 ± EXAMPLE 3
8W - 01 - 10 8W - 01 GENERAL INFORMATIONPL
DIAGNOSIS AND TESTING (Continued)

kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 16) (Fig. 17).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 18).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 18).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
Fig. 16 Terminal Removal
1 ± CONNECTOR
2 ± FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
1 ± FROM SPECIAL TOOL KIT 6680
2 ± CONNECTOR
PL8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)

(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).
(4) Position the connector locking finger away from
the terminal using the proper pick from special toolkit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires.
Fig. 18 Stagger Cutting Wires
1 ± REPAIR SIDE WIRES
2 ± STAGER CUTS
3 ± HARNESS WIRES
Fig. 19 Connector Locking Wedge Tab (Typical)
1 ± CONNECTOR
2 ± CONNECTOR LOCKING WEDGE TAB
Fig. 20 Terminal Removal
1 ± CONNECTOR
2 ± FROM SPECIAL TOOL KIT 6680
Fig. 21 Terminal Removal Using Special Tool
1 ± FROM SPECIAL TOOL KIT 6680
2 ± CONNECTOR
8W - 01 - 14 8W - 01 GENERAL INFORMATIONPL
SERVICE PROCEDURES (Continued)

²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 5). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. Thefollowing is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 5). In addition, suspect areas can be
checked by placing plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the scale pro-
vided on the package. Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications.Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
Fig. 6 Clearance Measurement
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)