1997 DODGE NEON service

Downloaded from www.Manualslib.com manuals search engine 8W-01 GENERAL INFORMATION
INDEX
page page
DESCRIPTION AND OPERATION
CIRCUIT IDENTIFICATION................. 3
CONNECTOR/GROUND LOCATIONS......... 1
CONNECTORS.......................... 3
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES.................... 5
FASTENERS............................ 5
HOW TO USE THIS GROUP................ 1
NOTES, CAUTIONS, and WARNINGS......... 2
POSITIVE TEMPERATURE COEFFICIENT..... 5
SECTION IDENTIFICATION................. 1
SPLICE LOCATIONS...................... 1
SYMBOLS.............................. 3
TAKE OUTS............................ 3
WIRE CODE IDENTIFICATION.............. 2
DIAGNOSIS AND TESTING
CHECKING FOR TERMINAL SPREADING...... 6INTERMITTENT AND POOR CONNECTIONS . . . 6
TROUBLESHOOTING TESTS............... 6
TROUBLESHOOTING TOOLS............... 5
TROUBLESHOOTING WIRING PROBLEMS.... 7
SERVICE PROCEDURES
CONNECTOR AND TERMINAL
REPLACEMENT........................ 9
CONNECTOR REPLACEMENT.............. 9
DIODE REPLACEMENT................... 11
FUSIBLE LINK REPLACEMENT............. 8
TERMINAL REPLACEMENT............... 10
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS........................ 8
WIRING REPAIR......................... 7
SPECIAL TOOLS
WIRING/TERMINAL...................... 11
DESCRIPTION AND OPERATION
HOW TO USE THIS GROUP
The purpose of this group is to show the electrical
circuits in a clear, simple fashion and to make trou-
bleshooting easier. Components that work together
are shown together. All electrical components used in
a specific system are shown on one diagram. The feed
for a system is shown at the top of the page. All
wires, connectors, splices, and components are shown
in the flow of current to the bottom of the page. Wir-
ing which is not part of the circuit represented is ref-
erenced to another page/section, where the complete
circuit is shown. In addition, all switches, compo-
nents, and modules are shown in theat rest posi-
tion with the doors closed and the key removed
from the ignition.
If a component is part of several different circuits,
it is shown in the diagram for each. For example, the
headlamp switch is the main part of the exterior
lighting, but it also affects the interior lighting and
the chime warning system.It is important to real-
ize that no attempt is made on the diagrams to
represent components and wiring as they
appear on the vehicle. For example, a short
piece of wire is treated the same as a long one.
In addition, switches and other components are
shown as simply as possible, with regard to
function only.
SECTION IDENTIFICATION
Sections in Group 8W are organized by sub-sys-
tems. The sections contain circuit operation descrip-
tions, helpful information, and system diagrams. The
intention is to organize information by system, con-
sistently from year to year.
CONNECTOR/GROUND 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.
PL8W - 01 GENERAL INFORMATION 8W - 01 - 1

Downloaded from www.Manualslib.com manuals search engine 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.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 1) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2)
Fig. 1 Wire Code Identification
Fig. 2 Wire Color Code Chart
8W - 01 - 2 8W - 01 GENERAL INFORMATIONPL
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 12).
(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 gauge be used as shown in the wir-
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable
Fig. 11 Testing for Continuity
Fig. 12 Testing for Voltage Drop
PL8W - 01 GENERAL INFORMATION 8W - 01 - 7
DIAGNOSIS AND TESTING (Continued)

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 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 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. 23).
(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.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 23 Diode Identification
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
PL8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine 8W-35 ANTI-LOCK BRAKES
INDEX
page page
DESCRIPTION AND OPERATION
ABS PUMP MOTOR RELAY................ 6
ABS SYSTEM RELAY..................... 6
ABS WARNING LAMP..................... 6
ANTI-LOCK BRAKES..................... 6BRAKE SWITCH INPUT................... 7
DATA LINK CONNECTOR.................. 7
HELPFUL INFORMATION.................. 7
HYDRAULIC MODULATOR................. 6
WHEEL SPEED SENSORS................. 7
DESCRIPTION AND OPERATION
ANTI-LOCK BRAKES
Power for the Anti-Lock brake system is supplied
by two fuses. There is a 15 amp fuse located in the
fuse block cavity 10. This fuse supplies power to the
Controller Anti Lock Brake (CAB), and the ABS sys-
tem relay on the F12 circuit. The F12 circuit also
supplies power to the Powertrain Control Module
(PCM). Power for the fuse is supplied on the A21 cir-
cuit from the ignition switch. This fuse is HOT in the
START/RUN position.
The second fuse is located in the Power Distribu-
tion Center (PDC). It is a 40 amp fuse. This fuse is
HOT at all times and supplies power to the contact
side of the ABS pump motor relay.
There are three grounding points used in the ABS
system. One is a case ground on the CAB. The sec-
ond is the Z12 circuit at the CAB connector cavity 5.
This ground is spliced, and terminates at the left side
of the radiator closure panel.
The third ground is on the Z1 circuit. This ground
is used for the ABS hydraulic modulator, ABS system
relay, and the ABS pump motor. This ground, like the
Z12 ground splices and terminates at the left head-
lamp ground.
Additional information on the circuit function of
the ABS system is listed below. For diagnostic and
testing procedures, refer to the appropriate section of
the Service Manual or the Diagnostic Test Proce-
dures Manual.
ABS WARNING LAMP
The ABS warning lamp is an output from the Con-
troller Anti Lock Brake (CAB) and the ABS relay
box. It is used to alert the operator of a problem in
the ABS system. The G19 circuit from the CAB and
the ABS system relay is used to detect a problem. If
a problem is detected, the CAB grounds the G19 cir-
cuit and illuminates the lamp in the instrument clus-
ter.
Circuit G19 is also an output of the CAB to the
ABS system relay contact side.
ABS SYSTEM RELAY
The system relay is used for the operation of the
ABS system. Power for the relay is supplied on the
B57 circuit from cavity 57 of the Controller Anti Lock
Brake (CAB).
Ground for the relay is on the Z1 circuit. This
ground is spliced in with the pump motor and termi-
nates at the left headlamp ground.
When the system is operating normally power for
the contact side of the relay is supplied from the
CAB on the B57 circuit. It passes through the relay
to the Z1 ground and terminates at the left headlamp
ground. If a problem is detected in the system, the
contact side of the relay switches from the Z1 to the
F12 circuit. This causes the ABS warning lamp in
the instrument cluster to illuminate.
ABS PUMP MOTOR RELAY
The ABS pump motor relay controls when the
pump motor runs. Power for the coil side of the relay
is supplied from cavity 47 of the Controller Anti Lock
Brake (CAB) on the B47 circuit. This circuit also sup-
plies voltage for the contact side of the system relay.
The ground side of the coil is controlled by the B116
circuit. Circuit B116 connects to cavity 16 of the CAB
connector.
Circuit B120 from cavity 20 of the CAB connector
powers the ABS pump motor. This circuit is also used
as an input to the CAB for pump motor monitoring.
HYDRAULIC MODULATOR
The hydraulic modulator is used for the controlling
of the brake system pressure to the wheels. The mod-
ulator is made up of four solenoids.
Circuits involved are, B142 for the left front wheel,
B143 for the right front wheel, B146 for the left rear
wheel, and B148 for the right rear wheel.
The solenoids use a common ground on the Z1 cir-
cuit. There are two Z1 circuits from the modulator.
Both of these grounds terminate at the left headlamp
ground, and are spliced in with the ABS pump motor
and the ABS system relay.
8W - 35 - 6 8W - 35 ANTI-LOCK BRAKESPL