1997 DODGE NEON length

Downloaded from www.Manualslib.com manuals search engine CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove the connector locking wedge, if
required (Fig. 16)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 17) (Fig. 18).
(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. 19).
(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 lengthfor soldered connections. Check that the overall
length is the same as the original (Fig. 19).
(7) Remove 1 inch of insulation from each wire.
Fig. 16 Connector Locking Wedge
Fig. 17 Terminal Removal
Fig. 18 Terminal Removal Using Special Tool
Fig. 19 Stagger Cutting Wires
PL8W - 01 GENERAL INFORMATION 8W - 01 - 9
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (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.
(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. 20).
(3) Remove connector locking wedge, if required
(Fig. 20).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 21) (Fig. 22).
(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.
(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.
Fig. 20 Connector Locking Wedge Tab (Typical)
Fig. 21 Terminal Removal
Fig. 22 Terminal Removal Using Special Tool
8W - 01 - 10 8W - 01 GENERAL INFORMATIONPL
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine ODOMETER
The speedometer and odometer receive their infor-
mation on the G7 circuit from the Vehicle Speed Sen-
sor (VSS) on vehicles equipped with the manual or
3±spd automatic transmission. This circuit also pro-
vides a signal to the Powertrain Control Module
(PCM).
Logic internal to the cluster steps the odometer at
a high rate to indicate the proper mileage.
SERVICE ENGINE SOON LAMP
The Service Engine Soon lamp illuminates when
the ignition switch is in the ON position and prior to
starting the vehicle. The lamp will turn off after the
vehicle is started.
If while the vehicle is running a problem is
detected in the engine control system the lamp is
illuminated. This is accomplished by the Powertrain
Control Module (PCM) grounding the G3 circuit.
SEAT BELT WARNING INDICATOR
The fasten seat belt indicator is used with the
warning chime to indicate to the operator to fasten
the seat belt. There is a switch located in the drivers
side B-pillar that is normally OPEN with the seat
belt buckled.
If the seat belt is not buckled the switch CLOSES
and a ground path is completed from the G10 circuit
to the Z1 circuit. This will illuminate the lamp in the
instrument cluster.
When the ignition switch is moved to the START
position the lamp will illuminate. Logic internal to
the instrument cluster determines the length of time.
LOW FUEL LAMP
The low fuel lamp is used to indicate to the opera-
tor that the fuel level is below a predetermined level.
This lamp is logic driven by the instrument cluster.
When the instrument cluster determines a low fuel
condition based on an input from the fuel tank gauge
level sending unit (circuit G4) it illuminates the
lamp.
HEADLAMP ON CHIME
The headlamp ON chime is used to indicate to the
operator that the headlamps or parking lamps are
ON when the drivers door is OPEN. If the lamps are
ON and the drivers door is opened, a ground path is
completed from the G26 circuit at the cluster,
through the headlamp switch, to the G16 circuit and
ending at the door ajar switch. The door ajar switch
is case grounded.
KEY-IN CHIME
The key-in chime is used to indicate to the opera-
tor that the key is in the ignition with the driversdoor OPEN. If the key is in the ignition and the driv-
ers door is OPEN, a ground path is completed from
the G26 circuit at the cluster, through the CLOSED
key-in switch, to the G16 circuit and terminating at
the door ajar switch which is case grounded.
CHARGE INDICATOR LAMP
The Charge Indicator lamp is used to alert the
operator that the charging system voltage has fallen
below the normal operating range. This circuit is con-
trolled by the Powertrain Control Module (PCM).
When the PCM determines a problem, it grounds the
G12 circuit.
AIRBAG WARNING LAMP
The Airbag Warning lamp is used to alert the oper-
ator of a problem with the Airbag system. The lamp
is illuminated when the Airbag Control Module
(ACM) grounds the R41 circuit. Refer to the appro-
priate section of the Service Manual or Diagnostic
Test Procedures Manual to diagnosis this system.
LOW OIL PRESSURE LAMP
The low oil pressure lamp is used to indicate to the
operator that the engine oil pressure has dropped
below a predetermined pressure. Power for the lamp
is provided on the G5 circuit which also powers the
other warning lamps.
When the oil pressure is low the normally OPEN
oil pressure switch CLOSES completing a path to
ground on circuit G6. The oil pressure switch is case
grounded to the engine block.
HIGH BEAM INDICATOR LAMP
The High Beam Indicator Lamp is used to indicate
to the operator that the high beam headlamps are
ON. Power is supplied to the cluster on the L3 cir-
cuit. Ground is provided on the Z3 circuit.
Circuit L3 connects from the headlamp dimmer
switch to the instrument cluster.
RIGHT AND LEFT TURN SIGNAL INDICATORS
These lamps are used to indicate to the operator
which turn signal is ON. Power for the lamps comes
from the turn signal switch. The L60 circuit is for the
right turn indicator, and the L61 circuit is used for
the left turn signal indicator. Ground for the circuits
is provided on the Z3 circuit.
BRAKE WARNING INDICATOR LAMP
The Brake Warning Indicator lamp is used to alert
the operator of a problem with the vehicles braking
system. The lamp illuminates when the ignition
switch is turned to START position to perform a self
check.
8W - 40 - 8 8W - 40 INSTRUMENT CLUSTERPL
DESCRIPTION AND OPERATION (Continued)