1999 DODGE NEON ignition

LAMPS
CONTENTS
page page
BULB APPLICATION...................... 13
HEADLAMP ALIGNMENT................... 4
LAMP BULB SERVICE..................... 6LAMP DIAGNOSIS........................ 1
LAMP SERVICE........................... 9
LAMP SYSTEMS......................... 12
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
DAYTIME RUNNING LAMP MODULE.......... 1
GENERAL INFORMATION.................. 1
SAFETY PRECAUTIONS................... 1DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 1
FOG LAMP.............................. 3
HEADLAMP DIAGNOSIS................... 2
GENERAL INFORMATION
GENERAL INFORMATION
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush and coat the inside of the socket lightly with
Mopar Multi-Purpose Grease or equivalent.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
DAYTIME RUNNING LAMP MODULE
PL vehicles built for use in Canada are equipped
with a Daytime Running Lamp (DRL) system. The
DRL system operates the headlamps at 50% illumi-
nation with the headlamp switch OFF, park brake
released and the ignition ON. The DRL system is
controlled by the Daytime Running Lamp Module.
The DRL module overrides the headlamp switch
when the headlamps are turned OFF. The headlamps
operate normally when the headlamps are turned
ON.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and
headlamp switch. Refer to Group 8W, Wiring Dia-
grams for component locations and circuit informa-
tion.
PLLAMPS 8L - 1

HEADLAMP DIAGNOSIS
Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Refer to Group 8W,
Wiring Diagrams.
Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on
a given vehicle.
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of-charge,
refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS
BURN OUT1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING1. Charging system output too low. 1. Test and repair charging system, refer to
Group 8A.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.5. Repair connector terminal or wire splice.
1. Headlamps stay on with
key out (DRLM equipped
vehicles).1. Failed DRLM 1. Replace DRLM.
*Canada vehicles must have lamps ON.
8L - 2 LAMPSPL
DIAGNOSIS AND TESTING (Continued)

FOG LAMP
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM WITH
ENGINE IDLING OR IGNITION
TURNED OFF.1. Loose or corroded battery cables. 1. Clean and secure battery cable
clamps and posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS ARE DIM WITH
ENGINE RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system.
Refer to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
2. High resistance in fog lamp
circuit.2. Test amperage draw of fog lamp
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.4. Repair connector terminal or wire
splice.
5. Defective or burned out bulb. 5. Replace bulb.
PLLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

BULB APPLICATION
INDEX
page page
SPECIFICATIONS
EXTERIOR LAMPS....................... 13GENERAL INFORMATION................. 13
INTERIOR LAMPS....................... 13
SPECIFICATIONS
GENERAL INFORMATION
The following Bulb Application Tables lists the
lamp title on the left side of the column and trade
number or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result. Do not
touch halogen bulbs with fingers or other oily sur-
faces. Bulb life will be reduced.
EXTERIOR LAMPS
LAMP BULB
Back-up...............................3157
Center High Mounted Stop..................921
Fog.................................GE881
Headlamp..............................9007
License Plate............................168
Park/Turn Signal......................3157NA
Tail/Stop/Turn Signal.....................3157
Front Side Marker........................168
INTERIOR LAMPS
Service procedures for most of the lamps in the
instrument panel, Instrument cluster and switches
are located in Group 8E, Instrument Panel and
Gauges.
LAMP BULB
A/C and Heater Control....................203
Ash Receiver.............................161
Cigar Lighter............................203
Dome Lamp.............................578
Gear Selector Console W/Auto...............161
Glove Compartment.......................194
Ignition Lock............................161
Instrument Panel and Cluster.............PC194
Rear Cargo..............................912
Underhood..............................105
PLLAMPS 8L - 13

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 8
SPECIFICATIONS
EXTERIOR LAMPS........................ 8INTERIOR LAMPS........................ 8
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Back-up...............................P21W
Center High Mounted Stop..................921
Front Fog Lamp..........................H-3
Headlamp...............................H-4
License Plate...........................W5W
Front Turn Signal.....................P21/5W
Tail/Stop.............................P21/5W
Rear Turn Signal.......................P21W
Rear Fog Lamp.........................P21W
Citylight...............................T4W
Side Repeater...........................T4W
INTERIOR LAMPS
LAMP BULB
ABS.................................PC194
Airbag...............................PC194
AshTray................................161
Brake Warning System Indicator...........PC194
Cigar Lighter............................203
Climate Controls.........................203
Console Gear Selector......................161
Dome Light..............................578
Glove Box...............................194
High Beam Indicator....................PC194
Ignition Key.............................161
Instrument Cluster.....................PC194
Rear Cargo..............................912
Seat Belt Indicator.......................PC74
Service Engine Soon....................PC194
Turn Signal Indicator....................PC194
Underhood..............................105
Visor Vanity.........................6501966
Volts Indicator..........................PC74
8L - 8 LAMPSPL

DIAGNOSIS AND TESTING
AIRBAG SYSTEM TEST
(1) Disconnect and isolate the negative battery
cable.
(2) Connect scan tool (DRB) to Data Link connec-
tor, located at right side of the steering column and
at the lower edge of the lower instrument panel.
(3) Turn the ignition key to ON position. Exit vehi-
cle with scan tool. Use the latest version of the
proper cartridge.
(4) After checking that no one is inside the vehicle,
connect the battery negative terminal.
(5) Using the scan tool, read and record active
diagnostic code data.
(6) Read and record any stored diagnostic codes.
(7) Refer to the Passive Restraint Diagnostic Test
Manual if any diagnostic codes are found in Step 5 or
Step 6.
(8) Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnos-
tic codes will not erase. Refer to the Passive
Restraint Diagnostic Test Manual to diagnose the
problem.If the airbag warning lamp either fails
to light with the ignition switch on, or the light
goes on and stays on, there is a system malfunc-
tion. Refer to the Passive Restraint Diagnostic
Test Manual to diagnose the problem.
SERVICE PROCEDURES
CLEANUP PROCEDURE
Roll or fold the passenger airbag towards the
instrument panel surface and close the door over the
folded bag. Then tape the door shut.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
4). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
vacuum cleaning may to necessary to decontaminate
the interior of the vehicle.
NOTE: Dispose deployed airbag properly, contact
dealer or government agency for disposal recom-
mendations.
SERVICE OF DEPLOYED AIRBAG MODULE
DRIVER AIRBAG
After a Driver Airbag Module has been deployed
the following components must be replaced becausethey cannot be reused. Other driver airbag system
components are replaced if damaged.
²Driver Airbag Module
²Clockspring assembly
PASSENGER AIRBAG
After a Passenger Airbag Module has been
deployed the following components must be replaced
because they cannot be reused.
²Passenger Airbag Module
²Right trim panel
The lower instrument panel knee blocker, top
cover, and any other components should be replaced
if damaged.
HANDLING AIRBAG MODULE
DEPLOYED MODULE
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED
The airbag module(s) must be stored in its original
special container until used for service. At no time
should a source of electricity be permitted near the
inflator on the back of an airbag module. When car-
rying or handling an undeployed airbag module, the
trim side of the airbag should be pointing away from
the body to minimize possibility of injury if acciden-
Fig. 4 Vacuum Heater and A/C Outlets
PLRESTRAINT SYSTEM 8M - 3

tal deployment occurs. Do not place undeployed air-
bag face down on a solid surface, the airbag will
propel into the air if accidental deployment occurs.
MAINTENANCE INSPECTION
(1) Check the airbag warning lamp for proper
operation as follows:
(a) Turn ignition switch to the ON position, the
airbag warning lamp should light. If not, test the
system using a scan tool and Passive Restraint
System Diagnostic Procedures Manual. Repair as
required.
(b) The airbag warning lamp lights, but fails to
go out after eight seconds. Test the system using a
scan tool and Passive Restraint System Diagnostic
Procedures Manual. Repair as required.
(c) After correcting active malfunction erase
stored diagnostic codes.
REMOVAL AND INSTALLATION
AIRBAG CONTROL MODULE (ACM)
REMOVAL
WARNING: THE ACM CONTAINS A SAFING SEN-
SOR WHICH ENABLES THE SYSTEM TO DEPLOY
THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOY-
MENT, NEVER CONNECT THE ACM ELECTRICALLY
TO THE SYSTEM WHILE VEHICLE BATTERY IS
CONNECTED.
DISCONNECT AND ISOLATE THE BATTERY NEG-
ATIVE (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 ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG
COMPONENTS.
CAUTION: Failure to follow the parking brake ser-
vice procedures can result in damage to the park-
ing brake mechanism.
(1) Disconnect and isolate the battery negative
cable.
(2) Manual transaxle only, remove shifter knob
fastener and remove shifter knob.
(3) Remove screws attaching rear of center console
assembly to console bracket (Fig. 5) or (Fig. 6).
(4) Remove the two screws located in cup holders
(Fig. 7), attaching front of center console assembly to
console bracket.
Fig. 5 Attaching Screws At Rear Of Center Console
With/Without Arm Rest
Fig. 6 Attaching Screws At Rear Of Center Console
With Arm Rest
Fig. 7 Attaching Screws At Front Of Center Console
8M - 4 RESTRAINT SYSTEMPL
SERVICE PROCEDURES (Continued)

CLOCKSPRING
REMOVAL
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 2 MINUTES BEFORE REMOV-
ING ANY AIRBAG COMPONENTS.
(1) Place the front road wheels in the straight
ahead position then:
²Rotate the steering wheel half turn (180
degrees) to the right (clockwise)
²Lock column with ignition lock cylinder.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the reserve capacitor to
discharge before removing non-deployed module.
(4) Remove speed control switch mounting screws,
switches and disconnect the wire connectors or
remove covers.
(5) Remove the Driver Airbag Module attaching
bolts from under the speed control switches or covers.
(6) Lift module and disconnect the airbag and horn
wire connectors.
(7) Remove the steering wheel, refer to Steering
Wheel removal procedures.
(8) Remove upper and lower steering column
shrouds to gain access to clockspring wiring.
(9) Disconnect the 2-way and 4-way connectors
between the clockspring and the instrument panel
wiring harness at the base of the clockspring (Fig.
21).
(10) Unlatch and remove clockspring assembly
from steering shaft. The clockspring cannot be
repaired, and must be replaced if faulty.
(11) Rotate clockspring rotor a half turn (180
degrees) to the left (counter clockwise).
(12) Lock the clockspring rotor in the center posi-
tion as follows: Insert a paper clip wire through the
hole in the rotor at the 10 O'clock position and bend
to prevent it from falling out.
INSTALLATION
(1) Confirm that:
²The steering wheel position is a half turn (180
degrees) to the right (clockwise)
²The column is locked with the ignition cylinder
lock.
²Check that the turn signal stalk is in the neu-
tral position²When reusing the clockspring, remove locking
wire and rotate clockspring rotor one half turn (180
degrees) to the right (clockwise). Locate the clock-
spring on the steering shaft and push down on the
rotor until the clockspring is fully seated on the
steering column.
²When installing a new clockspring remove gre-
nade pin and rotate clockspring rotor one half turn
(180 degrees) to the right (clockwise). Locate clock-
spring on the steering shaft and push down on the
rotor until the clockspring is fullly seated on the
steering wheel.
(2) Connect the clockspring to the instrument
panel harness, ensure wiring is properly routed.
Then check that the connectors, locking tabs are
properly engaged and the halo lamp wire is in posi-
tion.
(3) Install steering column shrouds. Be sure all
wires are inside of shrouds.
(4) Install steering wheel ensuring the flats on hub
align with the clockspring. Pull the horn, airbag and
speed control leads through the larger slot. Ensure
leads do not get pinched under the steering wheel.
(5) Route speed control wires under and behind
the airbag module mounting tabs.
(6) Connect the horn lead wire and the airbag lead
wire to the airbag module.
(7) Install the airbag module and tighten bolts to
12 to 14 N´m (105 to 125 in. lbs.) torque.
(8) Connect the speed control wires to the switches
and install switches. Tighten screws to 2 N´m (20 in.
lbs.) torque.
(9) Do not connect the battery negative cable.
Refer to Diagnosis and Testing for Airbag System
Test procedures.
Fig. 21 Clockspring
8M - 8 RESTRAINT SYSTEMPL
REMOVAL AND INSTALLATION (Continued)