1999 DODGE NEON Service Repair Manual

LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CITYLIGHT LAMP BULB.................... 3
FOG LAMP BULB......................... 3FRONT TURN SIGNAL LAMP BULB........... 2
HEADLAMP BULB........................ 2
SIDE REPEATER LAMP BULB............... 4
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Disengage wire connector to headlamp bulb.
(3) Remove headlamp assembly from vehicle.
(4) Remove rubber seal boot (Fig. 1).
(5) Disengage retaining ring from headlamp (Fig.
2).
(6) Pull headlamp bulb from back of headlamp
assembly (Fig. 3).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers of other possibly oily surface. Reduced
bulb life will result.
(1) Insert headlamp bulb to headlamp assembly.
(2) Install retaining ring to headlamp assembly.
(3) Install rubber seal boot.
(4) Engage wire connector to headlamp bulb base.
(5) Install headlamp assembly into vehicle.
(6) Verify headlamp alignment.
FRONT TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove screws holding the park and turn sig-
nal lamp to the headlamp assembly.
(2) Separate the turn signal lamp from the head-
lamp module.
(3) Rotate front turn signal lamp socket one quar-
ter turn counter-clockwise.
(4) Pull socket from back of lamp.
Fig. 1 Rubber Boot Seal
Fig. 2 Headlamp Bulb Retaining Ring
Fig. 3 Headlamp Bulb
8L - 2 LAMPSPL

(5) Pull bulb from socket (Fig. 4).
INSTALLATION
(1) Push bulb into socket.
(2) Insert socket into back of turn signal lamp.
(3) Rotate front turn signal socket clockwise one
quarter turn.
(4) Install front turn signal lamp onto vehicle.
(5) Verify lamp operation.
CITYLIGHT LAMP BULB
REMOVAL
(1) Pull citylight lamp socket from rubber bushing
in headlamp housing (Fig. 5).
(2) Rotate counterclockwise and pull bulb from
socket (Fig. 6).
INSTALLATION
(1) Position citylight lamp bulb to lamp socket.
(2) Push and twist bulb into socket.
(3) Push citylight lamp into bushing in headlamp
housing.
FOG LAMP BULB
REMOVAL
(1) Remove fog lamp assembly from fascia.
(2) Disengage fog lamp housing from bracket
assembly.
(3) Compress Wire Bulb Retainer (Fig. 7) on fog
lamp housing and pull away from lock tabs.
NOTE: Do not pull bulb from base.
(4) Disconnect Bulb Power and Ground Leads from
harness and bulb base. (Fig. 8).
INSTALLATION
CAUTION: Do not touch the glass of halogen
bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
(1) Align locator tabs and insert new bulb into fog
lamp housing.
(2) Connect Bulb Ground Lead to bulb base.
Fig. 4 Front Turn Signal Lamp Bulb
Fig. 5 Citylight Lamp Socket
Fig. 6 Citylight Lamp Bulb
Fig. 7 Wire Bulb Retainer
PLLAMPS 8L - 3
REMOVAL AND INSTALLATION (Continued)

(3) Connect Bulb Power Lead to Harness
(4) Compress Wire Bulb Retainer and engage into
lock tabs on fog lamp housing
(5) Install Fog Lamp Housing into Fog Lamp
Bracket.(6) Install Fog Lamp Assembly into fascia.
SIDE REPEATER LAMP BULB
REMOVAL
(1) Push lamp rearward.
(2) While pushing lamp, pry forward edge of lamp
away from car
(3) Pull lamp from hole
(4) Pull rubber boot away from lamp housing.
(5) Rotate and pull bulb from socket
INSTALLATION
(1) Align side repeater lamp bulb to socket
(2) Push and twist bulb into socket.
(3) Push rubber boot over lamp housing.
(4) Position side repeater lamp assembly to hole in
fender.
NOTE: The metal clip should be opposite of notch
in fender hole.
(5) Compress metal clip by pushing lamp rearward
(6) While pushing lamp assembly rearward, push
lamp into fender hole.
(7) Ensure that lamp is firmly attatched to body.
Fig. 8 Bulb Power and Ground Leads
8L - 4 LAMPSPL
REMOVAL AND INSTALLATION (Continued)

LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH............... 5
HEADLAMP SWITCH...................... 5
REMOVAL AND INSTALLATION
FOG LAMP.............................. 6HEADLAMP ASSEMBLY.................... 5
HEADLAMP LEVELING MOTOR.............. 6
SIDE REPEATER LAMP.................... 6
GENERAL INFORMATION
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch is incorporated into
the multi-function (turn signal) switch. Proper proce-
dures can be found in Group 8J, Turn Signal and
Flashers. More information can be found in Group
8W, Wiring Diagrams.
REMOVAL AND INSTALLATION
HEADLAMP ASSEMBLY
REMOVAL
(1) Release hood latch and open hood.
(2) Remove headlamp horizontal aim cable from
retainer clip on radiator upper crossmember.
(3) Disengage wire connector from leveling motor.
(4) Remove bolts holding headlamp leveling motor
to the upper radiator crossmember.
(5) Remove plastic locking cap holding vertical lev-
eling cable into leveling motor arm.
(6) Separate leveling cable from motor arm.
(7) Rotate leveling cable case one quarter turn
counter-clockwise and separate cable from motor
bracket.
(8) Separate leveling motor and bracket from vehi-
cle.
(9) From between front fascia and headlamp
assembly, remove bolt holding outboard end of
assembly to fender.
(10) Remove bolts holding inboard end of assembly
to radiator closure panel.
(11) Remove bolts holding top of assembly to upper
crossmember (Fig. 1).(12) Disengage wire connector from headlamp and
parking lamp sockets.
(13) Separate headlamp assembly from vehicle.
INSTALLATION
(1) Position headlamp assembly to vehicle.
(2) Route headlamp leveling cables through open-
ing in radiator closure panel.
(3) Engage wire connector to headlamp and park-
ing lamp sockets.
(4) Install bolts to hold top of assembly to upper
crossmember.
(5) Install bolts to hold inboard end of assembly to
radiator closure panel.
(6) Install bolt to hold outboard end of assembly to
fender.
(7) Position leveling motor and bracket to vehicle.
(8) Insert leveling cable through opening in level-
ing motor bracket.
(9) Rotate leveling cable case one quarter turn
clockwise.
(10) Engage leveling cable to leveling motor arm.
(11) Install plastic locking cap to hold leveling
cable into motor arm.
(12) Install bolts to hold leveling motor to upper
radiator crossmember.
(13) Engage wire connector to leveling motor.
(14) Engage horizontal aim cable to retainer clip
on upper radiator crossmember.
Fig. 1 Headlamp Assembly
PLLAMPS 8L - 5

(15) Verify lamp operation.
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Disengage wire connector from headlamp level-
ing motor.
(2) Remove bolts holding headlamp leveling motor
to upper radiator crossmember (Fig. 2).
(3) Remove plastic locking cap holding leveling
cable into motor arm (Fig. 3).
(4) Remove leveling cable from leveling motor arm.
(5) Rotate leveling cable case one quarter turn
counter-clockwise and separate cable from motor
bracket.
(6) Separate leveling motor from vehicle.
INSTALLATION
(1) Position headlamp leveling motor to vehicle.
(2) Insert leveling motor through hole in leveling
motor bracket.(3) Rotate leveling cable base one quarter turn
clockwise.
(4) Engage leveling cable to leveling motor arm.
(5) Engage plastic locking cap to hold leveling
cable into motor arm.
(6) Install bolts to hold headlamp leveling motor to
upper radiator crossmember.
(7) Engage wire connector to headlamp leveling
motor.
FOG LAMP
REMOVAL
(1) Remove nut holding fog lamp to radiator cross-
member (Fig. 4).
(2) Separate fog lamp from radiator crossmember.
(3) Pull fog lamp through opening in fascia.
(4) Disengage fog lamp wire connector from body
wiring harness.
(5) Separate fog lamp from vehicle.
INSTALLATION
(1) Position fog lamp to vehicle.
(2) Engage fog lamp wire connector to body wiring
harness.
(3) Insert fog lamp through opening in fascia.
(4) Position fog lamp to radiator crossmember.
(5) Install nut to hold fog lamp to radiator cross-
member.
SIDE REPEATER LAMP
REMOVAL
(1) Push Repeater Lamp Assembly Rearward
(2) While pushing Repeater Lamp Assembly rear-
ward, pry edge of lamp away from car.
(3) Pull Repeater Lamp Assembly from hole.
INSTALLATION
(1) Position Repeater Lamp Assembly in mounting
hole.
Fig. 2 Headlamp Leveling Motor
Fig. 3 Headlamp Leveling Cable From Leveling
Motor
Fig. 4 Fog Lamp
8L - 6 LAMPSPL
REMOVAL AND INSTALLATION (Continued)

NOTE: The metal clip on the Repeater Lamp
Assembly should be opposite from notch in fender
hole.
(2) Compress metal clip by pushing Repeater
Lamp Assembly rearward.(3) While pushing Repeater Lamp Assembly rear-
ward, push lamp into fender hole.
(4) Ensure that Repeater Lamp Assembly is firmly
attatched to body.
PLLAMPS 8L - 7
REMOVAL AND INSTALLATION (Continued)

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

RESTRAINT SYSTEM
CONTENTS
page page
GENERAL INFORMATION
WARNINGS AND PRECAUTIONS............ 1
DESCRIPTION AND OPERATION
AIRBAG CONTROL MODULE............... 1
CLOCKSPRING.......................... 2
DRIVER AND PASSENGER AIRBAG MODULE . . 2
DIAGNOSIS AND TESTING
AIRBAG SYSTEM TEST................... 3
SERVICE PROCEDURES
CLEANUP PROCEDURE................... 3HANDLING AIRBAG MODULE.............. 3
MAINTENANCE INSPECTION............... 4
REMOVAL AND INSTALLATION
AIRBAG CONTROL MODULE (ACM)......... 4
CLOCKSPRING.......................... 8
DRIVER AIRBAG MODULE................. 9
PASSENGER AIRBAG MODULE............. 9
STEERING WHEEL...................... 10
ADJUSTMENTS
CLOCKSPRING CENTERING PROCEDURE.... 11
GENERAL INFORMATION
WARNINGS AND PRECAUTIONS
WARNING: THIS SYSTEM IS A SENSITIVE, COM-
PLEX ELECTRO±MECHANICAL UNIT. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE
BEFORE BEGINNING AIRBAG SYSTEM COMPO-
NENT REMOVAL OR INSTALLATION PROCEDURES.
THIS WILL DISABLE THE AIRBAG SYSTEM. FAIL-
URE TO DISCONNECT THE BATTERY COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
DO NOT PLACE AN INTACT UNDEPLOYED AIR-
BAG FACE DOWN ON A SOLID SURFACE, THE AIR-
BAG WILL PROPEL INTO THE AIR IF
ACCIDENTALLY DEPLOYED AND COULD RESULT
IN PERSONAL INJURY. WHEN CARRYING OR HAN-
DLING AN UNDEPLOYED AIRBAG MODULE, THE
TRIM SIDE OF THE AIRBAG SHOULD BE POINTING
AWAY FROM THE BODY TO MINIMIZE POSSIBILITY
OF INJURY IF ACCIDENTAL DEPLOYMENT
OCCURS.
REPLACE AIRBAG SYSTEM COMPONENTS WITH
MOPARTREPLACEMENT PARTS. SUBSTITUTE
PARTS MAY APPEAR INTERCHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN INFE-
RIOR OCCUPANT PROTECTION.
WEAR SAFETY GLASSES, RUBBER GLOVES,
AND LONG SLEEVES CLOTHING WHEN CLEANING
POWDER RESIDUE FROM VEHICLE AFTER AIRBAG
DEPLOYMENT. SODIUM HYDROXIDE POWDER
RESIDUE EMITTED FROM A DEPLOYED AIRBAGCAN CAUSE SKIN IRRITATION. FLUSH AFFECTED
AREA WITH COOL WATER IF IRRITATION IS EXPE-
RIENCED. IF NASAL OR THROAT IRRITATION IS
EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR
UNTIL THE IRRITATION CEASES. IF IRRITATION
CONTINUES, SEE A PHYSICIAN.
DO NOT USE A REPLACEMENT AIRBAG THAT IS
NOT IN THE ORIGINAL PACKAGING, IMPROPER
DEPLOYMENT AND PERSONAL INJURY CAN
RESULT.
THE FACTORY INSTALLED FASTENERS,
SCREWS AND BOLTS USED TO FASTEN AIRBAG
COMPONENTS, ARE SPECIFICALLY DESIGNED
FOR THE AIRBAG SYSTEM. DO NOT USE SUBSTI-
TUTE FASTENERS, USE ONLY ORIGINAL EQUIP-
MENT FASTENERS LISTED IN THE PARTS
CATALOG WHEN FASTENER REPLACEMENT IS
REQUIRED.
NOTE: Airbags should be stored in a cool dry loca-
tion away from excessive heat and static electrical
activity with the fabric airbag facing UP, or a prema-
ture deployment can result.
If the Driver/Passenger Airbag Module is defective
and not deployed, refer to Chrysler Corporation cur-
rent return list for proper handling procedures.
DESCRIPTION AND OPERATION
AIRBAG CONTROL MODULE
The Airbag Control Module (ACM) contains the
safing sensor and energy reserve capacitor. The saf-
ing sensor is located inside the ACM. The module is
mounted on the tunnel/floor pan between the gear
PLRESTRAINT SYSTEM 8M - 1