1997 DODGE NEON Generator

Downloaded from www.Manualslib.com manuals search engine (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. 13)
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 13)
(6) Twist the wires together (example 3) (Fig. 13)
(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.
FUSIBLE LINK REPLACEMENT
On PL vehicles there is a fusible link placed
between the output terminal of the generator and the
engine starter motor terminal. A service part is avail-
able if this fusible link requires replacement.
This service part has the eyelet that attaches to
the starter motor. If the fusible link requires replace-ment this indicates a problem in the charging/start-
ing system that needs to be corrected.
Replacement of the fusible link is the same as
repairing a wire. Refer to the wiring repair informa-
tion in this section for soldering information.
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 14).
(4) Using special tool 6742 release the locking fin-
gers on the terminal (Fig. 15).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal, as
necessary.
Fig. 13 Wire Repair
Fig. 14 Molex Connector Repair
Fig. 15 Using Special Tool 6742
8W - 01 - 8 8W - 01 GENERAL INFORMATIONPL
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine 8W-02 COMPONENT INDEX
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION.......................................................... 3
Component Page
A/C Compressor Clutch.................8W-42
A/C Compressor Clutch Relay............8W-42
A/C Cycling Switch....................8W-42
A/C Heater Blower Motor................8W-42
A/C Heater Control Switch...............8W-42
A/C High Pressure Switch...............8W-42
A/C Low Pressure Switch................8W-42
ABS Hydraulic Modulator...............8W-35
ABS Pump Motor......................8W-35
ABS Pump Motor Relay.................8W-35
ABS Relay Box........................8W-35
ABS System Relay.....................8W-35
ABS Warning Lamp....................8W-35
Airbag Control Module..................8W-43
Airbag Impact Sensors..................8W-43
Airbag Warning Lamp..................8W-40
Antenna.............................8W-47
Anti-Lock Warning Lamp................8W-40
Ash Receiver Lamp....................8W-44
Automatic Shut Down Relay.............8W-30
Back-Up Lamp Switch..................8W-51
Back-Up Lamps.......................8W-51
Battery..............................8W-20
Battery Temperature Sensor.............8W-30
Blower Motor Resistor Block.............8W-42
Brake Warning Lamp...................8W-40
Brake Warning Lamp Switch.............8W-40
Camshaft Position (CMP) Sensor..........8W-30
Capacitor.........................8W-10, 20
Charge Indicator Lamp.................8W-40
Check Engine Lamp....................8W-40
Cigar Lighter Relay....................8W-41
Cigar Lighter/Power Outlet..............8W-41
Circuit Breaker.....................8W-11,62
Circuit Breaker (FB)...................8W-11
Clockspring..........................8W-41
Cluster Illumination Lamps..............8W-40
Clutch Pedal Position Switch..........8W-10, 21
Combination Flasher...................8W-52
Controller Anti-Lock Brake..............8W-35
Crankshaft Position (CKP) Sensor.........8W-30
Data Link Connector...................8W-30
Diode............................8W-15, 42
Dome Lamp..........................8W-44Component Page
Door Ajar Switches.....................8W-44
Door Jamb Switches....................8W-40
Door Lock Motors......................8W-61
Door Lock Switches....................8W-61
Door Speakers........................8W-47
Driver Side Airbag.....................8W-43
Duty Cycle Evap/Purge Solenoid..........8W-30
EGR Transducer Solenoid...............8W-30
Engine Coolant Temperature (ECT) Sensor . . 8W-30
Engine Coolant Temperature Gauge.......8W-40
Engine Oil Pressure Switch..............8W-40
Engine Starter Motor...................8W-21
Engine Starter Motor Relay..............8W-21
Fog Lamp Relay....................8W-50, 51
Fog Lamps........................8W-50, 51
Front Fog Lamp Switch.................8W-50
Fuel Gauge...........................8W-40
Fuel Injectors.........................8W-30
Fuel Pump Module.....................8W-30
Fuel Pump Relay......................8W-30
Fuse Block...........................8W-11
Fuses (FB)...........................8W-11
Fuses (PDC)..........................8W-10
Fusible Link.......................8W-20, 21
Generator............................8W-20
Glove Box Lamp And Switch.............8W-44
Ground Distribution....................8W-15
Headlamp Dimmer And Optical
Horn Switch........................8W-50
Headlamp Leveling Motors..............8W-50
Headlamp Leveling Switch...............8W-50
Headlamp Switch......................8W-50
Headlamps...........................8W-50
Heated Oxygen Sensors.................8W-30
High Beam Indicator Lamp..............8W-40
Horn Relay...........................8W-41
Horn Switches........................8W-41
Horns...............................8W-41
IAT/MAP Sensor......................8W-30
Idle Air Control (IAC) Motor.............8W-30
Ignition Coil Pack.....................8W-30
Ignition Switch........................8W-10
Immobilizer Engine Sensor..............8W-30
Immobilizer Sensor....................8W-30
PL8W - 02 COMPONENT INDEX 8W - 02 - 1

Downloaded from www.Manualslib.com manuals search engine 8W-10 POWER DISTRIBUTION
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION......................................................... 13
Component Page
A/C Compressor Clutch..................8W-10-9
A/C Compressor Clutch Relay.............8W-10-9
ABS Relay Box........................8W-10-7
Automatic Shut Down Relay.............8W-10-10
Battery.............................8W-10-4
Capacitor...........................8W-10-10
Circuit Breaker.......................8W-10-6
Clutch Pedal Position Switch.............8W-10-12
Data Link Connector...................8W-10-10
Dome Lamp..........................8W-10-8
Downstream Heated Oxygen Sensor........8W-10-10
Engine Starter Motor...................8W-10-5
Engine Starter Motor Relay............8W-10-5, 12
Engine Starter Motor Relay...............8W-10-5
Fog Lamp Relay......................8W-10-11
Fuel Injector No. 1....................8W-10-10
Fuel Injector No. 2....................8W-10-10
Fuel Injector No. 3....................8W-10-10
Fuel Injector No. 4....................8W-10-10
Fuel Pump Module....................8W-10-10
Fuel Pump Relay.....................8W-10-10
Fuse 1 (FB)..........................8W-10-6
Fuse 2 (PDC).......................8W-10-4, 5
Fuse 3 (PDC).......................8W-10-4, 6
Fuse 4 (FB)..........................8W-10-6
Fuse 5 (FB)..........................8W-10-6
Fuse 5 (PDC).......................8W-10-4, 7
Fuse 6 (FB)..........................8W-10-6
Fuse 7 (FB)..........................8W-10-6
Fuse 8 (FB)..........................8W-10-6
Fuse 8 (PDC).......................8W-10-4, 7
Fuse 10 (FB).........................8W-10-12
Fuse 10 (PDC)......................8W-10-4, 7
Fuse 11 (FB).........................8W-10-12
Fuse 11 (PDC)......................8W-10-4, 5
Fuse 12 (FB).........................8W-10-12
Fuse 13 (PDC)......................8W-10-4, 8
Fuse 14 (FB).........................8W-10-12
Fuse 15 (FB).........................8W-10-12
Fuse 16 (FB).........................8W-10-12
Fuse 16 (PDC)......................8W-10-4, 11
Fuse 18 (PDC)......................8W-10-4, 9
Fuse 20 (PDC)......................8W-10-4, 9
Fuse 21 (PDC)......................8W-10-4, 10
Component Page
Fuse 23 (PDC)......................8W-10-4, 10
Fuse 25 (PDC)......................8W-10-4, 9
Fuse Block........................8W-10-6, 12
G204...............................8W-10-5
Generator...........................8W-10-10
Glove Box Lamp And Switch..............8W-10-8
Headlamp Switch......................8W-10-6
Horn No. 1...........................8W-10-9
Horn No. 2...........................8W-10-9
Horn Relay..........................8W-10-9
Ignition Coil Pack.....................8W-10-10
Ignition Switch...................8W-10-5, 6, 12
Instrument Cluster...................8W-10-5, 8
Left Fog Lamp.......................8W-10-11
Left Visor/Vanity Lamps.................8W-10-8
Map/Reading Lamps....................8W-10-8
Noise Supressor......................8W-10-10
Power Distribution Center...............8W-10-10
Power Distribution Center . . 8W-10-4, 5, 6, 7, 8, 9, 10, 11
Powertrain Control Module..............8W-10-10
Radiator Fan Motor....................8W-10-7
Radio...............................8W-10-8
Rear Fog Lamp Switch.................8W-10-11
Rear Window Defogger Switch.............8W-10-7
Right Fog Lamp......................8W-10-11
Right Visor/Vanity Lamps................8W-10-8
S105..............................8W-10-10
S115 ..............................8W-10-11
S121..............................8W-10-10
S122..............................8W-10-10
S131...............................8W-10-9
S134..............................8W-10-10
S202...............................8W-10-5
S203...............................8W-10-8
S208...............................8W-10-5
S213...............................8W-10-6
S217...............................8W-10-6
S309...............................8W-10-8
Solid State Fan Relay...................8W-10-7
Stop Lamp Switch.....................8W-10-9
Trunk Lamp..........................8W-10-8
Turn Signal/Hazard Switch...............8W-10-9
Underhood Lamp......................8W-10-8
Upstream Heated Oxygen Sensor..........8W-10-10
8W - 10 - 2 8W - 10 POWER DISTRIBUTIONPL

Downloaded from www.Manualslib.com manuals search engine 21FUSE20A
21
52
55
60
57
BATT A0
POWER
DISTRIBUTION
CENTER
72
C14616
A14
16
RD/WT
A14
16
RD/WT
POWERTRAIN
CONTROL
MODULE
A14
18
RD/WT
6C105
A141
16
DG/WT
A141
18
DG/WT
4
FUEL
PUMP
MODULE
A142
18
DG/OR
S105
22
FUEL
PUMP
RELAYAUTOMATIC
SHUT
DOWN
RELAY
CONNECTORLINK DATA
6C161
DG/OR18 A142
GENERATOR
A142
18
DG/OR
SENSOR OXYGEN
HEATED
DOWNSTREAM
A142
18
DG/OR
POWERTRAIN
CONTROL
MODULE
SENSOR OXYGEN
HEATED
UPSTREAM
A142
18
DG/ORA142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR A142
18
DG/ORDG/OR18 A142
DG/OR18 A142 A142
18
DG/OR
IGNITION
COIL
PACKSUPRESSOR
NOISE
S134S121
S122
2
DG/OR18 A142
DG/OR14 A142
2222
1161C2
58
FUEL
INJECTOR
NO. 1 NO. 2INJECTOR
FUEL FUEL
INJECTOR
NO. 3FUEL
INJECTOR
NO. 4
CAPACITOR
(8W-30-2) (8W-30-10)(8W-10-4)
(8W-30-10)
(8W-30-2)(8W-10-4)
(8W-30-4)
(8W-20-2)
(8W-30-3)(8W-30-2)
(8W-30-3)
(8W-30-5) (8W-30-5) (8W-30-5) (8W-30-5) (8W-30-5)
(8W-30-5)
8W - 10 - 10 8W-10 POWER DISTRIBUTIONPL-RHD
978W-1PLR01009

Downloaded from www.Manualslib.com manuals search engine 8W-20 CHARGING SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION.......................................................... 3
Component Page
Automatic Shut Down Relay............8W-20-2
Battery............................8W-20-2
Capacitor...........................8W-20-2
Engine Starter Motor.................8W-20-2
Fuse 21 (PDC).......................8W-20-2
Fusible Link........................8W-20-2
G104..............................8W-20-2Component Page
G105..............................8W-20-2
Generator..........................8W-20-2
Power Distribution Center.............8W-20-2
Powertrain Control Module.............8W-20-2
S122..............................8W-20-2
S125..............................8W-20-2
8W - 20 - 2 8W - 20 CHARGING SYSTEMPL

Downloaded from www.Manualslib.com manuals search engine GENERATOR
ENGINE
STARTER
MOTOR
C24
GENERATOR
FIELD
DRIVERPOWERTRAIN
CONTROL
MODULE
K20
18
DG
A11
12
BK
A11
8
BK/GY
S125
21FUSE20A
21
57
60
POWER
DISTRIBUTION
CENTER BATTERY
A0
6
RD
A0 8RD
Z0
8
BK
Z1
10
BK
G104 G105
A142
18
DG/OR
6C161
A142
18
DG/OR
A142
18
DG/OR
S122
22
1
2
AUTOMATIC
SHUT
DOWN
RELAY
LINK FUSIBLE
CAPACITOR
(8W-30-11) (8W-10-10)(8W-10-4)
(8W-15-5) (8W-15-5)
(8W-10-10)
(8W-21-2)(8W-30-2)
8W - 20 - 2 8W-20 CHARGING SYSTEMPL-RHD
PL8W - 20 CHARGING SYSTEM 8W - 20 - 3
GENERAL INFORMATION (Continued)

Downloaded from www.Manualslib.com manuals search engine 8W-20 CHARGING SYSTEM
DESCRIPTION AND OPERATION
CHARGING SYSTEM
The charging system is an integral part of the bat-
tery and starter systems. Since all of these systems
work together, any diagnosis and testing should be
done in conjunction.
The charging system is protected by a 12 gauge
fusible link located in the A11 circuit. This fusible
link is between the generator and the starter.
The generator ground is provided through a case
ground in the generator to its attaching bracket. This
generator uses a voltage regulator internal to the
Powertrain Control Module (PCM).
When the vehicle is running, battery voltage is
applied to the generator field terminal through the
A142 circuit. This circuit is the output from the con-
tact side of the Automatic Shut Down (ASD) relay.
The ground, or voltage regulated side, of the genera-
tor field is controlled by the K20 circuit which con-
nects to cavity 4 of the PCM connector.
When there is current present in the field, and the
rotor is turning, the stator in the generator produces
a B+ voltage that is supplied to the battery through
the A11 and A0 circuits. The A11 circuit is connected
to the output terminal of the generator and connects
to the engine starter motor battery feed terminal.
The A0 circuit is a direct feed line from the battery
and connects to the engine starter motor.
Grounding for the system is accomplished at the
battery negative terminal. These grounds connect to
the engine and body.
HELPFUL INFORMATION
²Inspect for a blown fusible link in the A11 cir-
cuit between the generator and the starter motor.
²For additional information on charging system
diagnosis, refer to the appropriate section of the ser-
vice manual.
PL8W - 20 CHARGING SYSTEM 8W - 20 - 3

Downloaded from www.Manualslib.com manuals search engine 8W-21 STARTING SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS........................................................... 1
DESCRIPTION AND OPERATION.......................................................... 3
Component Page
Battery............................8W-21-2
Clutch Pedal Position Switch...........8W-21-2
Engine Starter Motor.................8W-21-2
Engine Starter Motor Relay............8W-21-2
Fuse 11 (PDC).......................8W-21-2
Fusible Link........................8W-21-2
G101..............................8W-21-2
Generator..........................8W-21-2Component Page
Ignition Switch......................8W-21-2
Park/Neutral Position Switch...........8W-21-2
Power Distribution Center.............8W-21-2
Powertrain Control Module.............8W-21-2
S106..............................8W-21-2
S107..............................8W-21-2
S125..............................8W-21-2
S127..............................8W-21-2
8W - 21 - 2 8W - 21 STARTING SYSTEMPL