wiring DODGE NEON 2000 Service Manual Online

(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)

(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) 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.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys-
tems.
Fig. 22 Diode Identification
1 ± CURRENT FLOW
2 ± BAND AROUND DIODE INDICATES CURRENT FLOW
3 ± DIODE AS SHOWN IN THE DIAGRAMS
PL8W - 01 GENERAL INFORMATION 8W - 01 - 15
SERVICE PROCEDURES (Continued)

SPECIAL TOOLS
WIRING/TERMINAL
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W - 01 - 16 8W - 01 GENERAL INFORMATIONPL

8W-90 CONNECTOR/GROUND LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-
nector index is provided. Use the wiring diagrams ineach section for connector number identification.
Refer to the index for the proper figure number.CONNECTOR/GROUND LOCATIONS (LHD)
For items not shown in this section a N/S is placed
in the Fig. column.
Connector
Name/NumberColor Location Fig.
A/C
Compressor
ClutchBK Right Front of
Engine
Compartment3
A/C Cycling
SwitchBK Right Side of
Instrument
PanelN/S
A/C-Heater
Blower MotorBK Right Side of
Instrument
PanelN/S
A/C-Heater
ControlGY Center of
Instrument
Panel7
A/C High
Pressure
SwitchBK Front Center
of Engine
Compartment1, 3
A/C Low
Pressure
SwitchBK Right Rear of
Engine
Compartment1, 3
Airbag Control
ModuleYL Near PRNDL
Lamp T/O6
Back-Up Lamp
Switch (MTX)GY Left Front of
Engine
Compartment2
Blower Motor
Resistor BlockBK T/O Near
Grommet and
C202N/S
Brake Lamp
SwitchGY Top of Brake
Pedal2
Brake Shift
Interlock
SolenoidWT Left Side of
Instrument
PanelN/S
Brake Warning
Indicator
SwitchBK Near Left
Front Strut
Tower2
C101 BK Left Front of
Engine
Compartment2, 4Connector
Name/NumberColor Location Fig.
C102 LT GY Left Front of
Engine
Compartment2, 4
C103 BK Left Side of
Instrument
Panel2, 6, 8
C104 GY Left Side of
Instrument
Panel2, 6, 8
C105 BK At Left Kick
Panel Area2, 10
C106 BK Left Rear of
Engine
Compartment2
C107 BK Near Left
Front Strut
Tower2
C108 BK Left Front of
Engine
Compartment2
C109 BK Right Inner
Fender1
C110 BK Left
Headlamp
Opening2
C111 BK Right
Headlamp
Opening3
C201 GY Right Side of
Instrument
Panel6, 15
C202 LT GN Right Side of
Instrument
Panel6, 7
C203 LT GY Right Side of
Instrument
Panel6, 7
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1

8W-95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of the splices in this vehicle. A splice
index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for proper splice number.
SPLICE LOCATIONS (LHD)
The following index covers all splices shown in the
wiring diagrams. If a splice is not shown in this sec-
tion, a N/S will be in the Fig. column.
Spllice Location Fig.
S102 (Except
Built-Up-
Export)Near Left Headlamp T/O 2
S103 Left Side of Instrument
Panel3
S104 Left Side of Instrument
Panel3
S105
(Built-Up-
Export)Left Side of Instrument
Panel3
S106 Near Left Strut Tower 3
S107 Near A/C Low Pressure
Switch T/O3
S108 Near Controller Anti-Lock
Brake3
S109 Near Power Distribution
Center3
S110 Near Radiator Fan Motor
T/O3
S 111
(Built-Up-
Export)Same as S102 2
S112 Near Back-Up Lamp
Switch T/O3
S113 Near Throttle Position
Sensor T/O3
S114 Near Throttle Position
Sensor T/O3
S116
(Built-Up-
Export)Near C110 T/O 3
S117 Near Right Front Side
Marker or Right Repeater
Lamp T/O2
S118 Near Powertrain Control
Module - C2 T/O3Spllice Location Fig.
S119 Near Radiator Fan Motor
T/O3
S120
(Built-Up-
Export)Near Siren T/O 1
S121 Near Fuel Injector NO. 4
T/O4
S122 Near Engine Oil Pressure
Switch T/O5
S123 Near Crankshaft Position
Sensor T/O5
S125 Near Manifold Absolute
Pressure Sensor T/O4
S129 (2.0L) Near Noise Suppressor
T/O5
S130 Near Ignition Coil T/O 5
S131 Near Left Headlamp T/O 2
S132 Near Left Strut Tower 3
S141 Near High Note Horn T/O N/S
S142 Near High Note Horn T/O N/S
S201 Near Right Instrument
Panel Speaker T/O6
S202 Near C202 and C203
T/O6
S203 Near C202 and C203
T/O6
S204 In C202 and C203 T/O 6
S205 Near C202 and C203
T/O6
S206 Near Center of
Instrument Panel6
S207 Near Center of
Instrument Panel6
S208 Near Instrument Cluster
T/O6
PL8W - 95 SPLICE LOCATIONS 8W - 95 - 1

SPLICE LOCATIONS (RHD)
The following index covers all splices shown in the
wiring diagrams. If a splice is not shown in this sec-
tion, a N/S will be in the Fig. column.
Spllice Location Fig.
S103 Near C104 and C103
T/O19
S104 In Data Link Connector
T/O19
S105 Near Grommet 19
S106 Near Left Strut Tower 16
S107 Near Brake Warning
Indicator Switch T/O16
S108 In Controller Anti-Lock
Brake T/O16
S109 Near Power Distribution
Center16
S110 Near Radiator Fan Motor
T/O16
S111 Near Left Headlamp T/O 15
S112 Near Left Strut Tower 16
S113 Near Throttle Position
Sensor T/O16
S114 Near Idle Air Control
Motor T/O16
S116 Near C110 T/O 16
S117 Near Repeater Lamp T/O 15
S118 Near Powertrain Control
Module - C2 T/O16
S119 Near A/C High Pressure
Switch T/O16
S120 Near Siren T/O 14
S121 Near Fuel Injector NO. 4
T/O17
S122 Near Engine Oil Pressure
Switch T/O18
S123 Near Crankshaft Position
Sensor T/O18
S125 Near Manifold Absolute
Pressure Sensor T/O17
S129 (2.0L) Near Noise Suppressor
T/O18
S130 Near Ignition Coil T/O 18
S131 Right Front of Engine
Compartment15
S132 Near Left Strut Tower 16Spllice Location Fig.
S141 Near High Note Horn T/O N/S
S142 Near High Note Horn T/O N/S
S201 Near Left Instrument
Panel Speaker20
S202 Left Side of Instrument
Panel20
S203 Left Side of Instrument
Panel20
S204 Near C202 T/O 20
S205 Left Side of Instrument
Panel20
S206 Left Side of Instrument
Panel20
S207 Near Instrument Cluster
T/O20
S208 Near Instrument Cluster
T/O20
S209 Near Brake Shift
Interlock Solenoid T/ON/S
S211 Near Right Instrument
Panel Speaker T/O20
S212 Near Instrument Cluster
T/O20
S213 Near Instrument Cluster
T/O20
S214 Near Instrument Cluster
T/O20
S215 Near Right Instrument
Panel Speaker T/O20
S216 Near Right Instrument
Panel Speaker T/O20
S217 Near Right Instrument
Panel Speaker T/O20
S218 Near Right Instrument
Panel Speaker T/O20
S219 Near Right Instrument
Panel Speaker T/O20
S220 Near Right Instrument
Panel Speaker T/O20
S221 Near Right Instrument
Panel Speaker T/O20
PL8W - 95 SPLICE LOCATIONS 8W - 95 - 13
DESCRIPTION AND OPERATION (Continued)

(4) Discharge air conditioning system, if equipped.
Refer to Group 24, Heating and Air Conditioning for
procedure.
(5) Disconnect the following: air intake duct at
intake manifold, throttle cables, electrical connectors
from throttle body and air cleaner housing.
(6) Remove air cleaner housing assembly.
(7) Remove upper radiator hose and fan module.
Refer to Group 7, Cooling System for procedure.
(8) Remove lower radiator hose.
(9) Disconnect automatic transmission cooler lines
and plug, if equipped.
(10) Disconnect shift linkage, electrical connectors,
and clutch cable, if equipped with manual transaxle.
(11) Disconnect engine wiring harness.
(12) Disconnect positive cable from Power Distri-
bution Center (PDC) and ground wire from vehicle
body.
(13) Disconnect ground wire from the vehicle body-
to-engine at the right side strut tower.
(14) Disconnect heater hoses.
(15) Disconnect vacuum hose from brake booster.
(16) Disconnect coolant reserve/recovery hose.
(17) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(18) Remove power steering pump and reservoir
and set them aside.
(19) Hoist vehicle and remove right inner splash
shield.
(20) Drain engine oil.
(21) Remove front wheels.
(22) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(23) Disconnect exhaust system from manifold.
(24) Disconnect the downstream oxygen sensor
connector.
(25) Remove lower engine torque strut.
(26) Remove structural collar. Refer to procedure
in this section.
(27) Lower vehicle and remove A/C compressor.
(28) Raise vehicle enough to allow engine dolly
and cradle, Special Tools 6135 and 6710 to be
installed under vehicle.
(29) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 26). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(30) Install safety straps around the engine to cra-
dle (Fig. 26). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used.(31) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(32) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(33) Remove the upper engine torque strut.
(34) Remove right and left engine and transaxle
mount through bolts (Fig. 24) and (Fig. 25).
(35) Raise vehicle slowly until body is approxi-
mately 15 cm (6 in.) above normal engine mounting
locations.
(36) Remove generator, lower bracket, and upper
mounting bolt.
(37) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary to move the engine/transmission
assembly with the cradle to allow for removal around
body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly until vehicle is within 15
cm (6 in.) of engine mounting locations.
(2) Install generator, lower bracket, and adjusting
bolt.
(3) Continue lowering vehicle until engine/tran-
saxle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 24) and (Fig. 25). Tighten bolts to 118 N´m (87
ft. lbs.).
(4) Install upper engine torque strut. Refer to pro-
cedure in this section.
(5) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(6) Install axle shafts. Refer to Group 3, Differen-
tial and Driveline for procedure.
(7) Install structural collar. Refer to procedure in
this section tightening sequence.
Fig. 24 Right Mount Through Bolt
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
9 - 26 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install lower engine torque strut. Refer to pro-
cedure in this section.
(9) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System for procedure and torque
specifications.
(10) Connect the downstream oxygen sensor.
(11) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(12) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(13) Install inner splash shield.
(14) Install wheels and lower vehicle.
(15) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(16)Manual Transmission:Connect clutch cable,
reverse light electrical connector and shift linkages.
Refer to Group 6, Clutch.
(17)Automatic Transmission:Connect shifter,
kickdown linkage and cooler lines. Refer to Group 21,
Transaxle for procedures.
(18) Connect fuel line and heater hoses.
(19)
Install all ground straps. Connect engine wiring
harness. Refer to Group 8, Electrical for procedure.
(20) Install lower radiator hose, fan module, and
upper radiator hose. Refer to Group 7, Cooling Sys-
tem for procedures
(21) Fill cooling system. Refer to Group 7, Cooling
System for filling procedure.
(22) Install battery tray and battery.
(23) Install air cleaner housing assembly and con-
nect intake duct to intake manifold.(24) Connect all throttle body electrical connectors
and linkage.
(25) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(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.
Fig. 25 Left Mount Through Bolt
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
Fig. 26 Positioning Engine Cradle Support Post
1 ± SAFETY STRAPS
2 ± PLACE REAR POSTS INTO LOCATING HOLES
3 ± SPECIAL TOOL 6848
4 ± SPECIAL TOOL 6710
5 ± SPECIAL TOOL 6135
6 ± SAFETY STRAPS
7 ± PLACE FRONT POST UNDER BLOCK FLANGE
PL2.0L SOHC ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)

(27) Start engine and run until operating temper-
ature is reached.
(28) Ensure engine is properly positioned. Refer to
Torque Struts in this section for adjustment proce-
dure.
(29) Adjust transmission linkage, if necessary.
INTAKE MANIFOLD
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove the inlet air duct from intake manifold
to throttle body.
(3) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System for procedures.
WARNING: WRAP SHOP TOWELS AROUND FUEL
HOSE TO CATCH ANY GASOLINE SPILLAGE
(4) Disconnect fuel supply line quick connect at the
fuel tube assembly. Refer to Group 14, Fuel System
for procedures.
(5) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
(6) Disconnect brake booster hose (Fig. 27) and
PCV hose (Fig. 28) from intake manifold.
(7) Disconnect Manifold Absolute Pressure (MAP)
sensor electrical connector (Fig. 29).
(8) Disconnect knock sensor electrical connector
(Fig. 30).
(9) Disconnect wiring at starter.
(10) Remove the intake manifold to lower support
bracket bolts (Fig. 31).
(11) Remove intake manifold screws and washers.
Discard the fasteners. Remove intake manifold.
INSTALLATION
Before installing manifold. Clean all mating sur-
faces. Replace all O-ring gaskets with new gaskets
(Fig. 33). All intake manifold fasteners and washers
are to be discarded andNEWfasteners and washers
are to be used.(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 N´m (105 in. lbs.) in sequence
shown in (Fig. 32).
Fig. 27 Brake Booster Hose
Fig. 28 PCV Hose
9 - 28 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)