1999 DODGE NEON service indicator

JUMP STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS............ 9JUMP STARTING PROCEDURE.............. 7
TOWING RECOMMENDATIONS.............. 8
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, placethe automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
PLLUBRICATION AND MAINTENANCE 0 - 7

DRUM BRAKE AUTOMATIC ADJUSTER
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the rear adjustment slot in each brake
support plate to provide access to the adjuster star
wheel. Then, to eliminate the possibility of maximum
adjustment, back the star wheel off approximately 10
notches. It will be necessary to hold the adjuster
lever away from the star wheel to permit this adjust-
ment.
Apply the brake pedal. This application of force
will cause the brake shoes to leave the anchor. Upon
application of the brake pedal, the lever should move
downward, turning the star wheel. Thus, a definite
rotation of the adjuster star wheel can be observed if
the automatic adjuster is working properly. If one or
more adjusters do not function properly, the respec-
tive drum must be removed for adjuster servicing.
ROTOR THICKNESS AND RUNOUT
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Before refinishing or refacing a rotor, the disc
should be checked and inspected for the following
conditions:
Braking surface scoring, rust, impregnation of lin-
ing material and worn ridges.
Excessive lateral runout or wobble.
Thickness variation (Parallelism).
Dishing or distortion (Flatness).
If a vehicle has not been driven for a period of
time, the rotor surface will rust in the area not cov-
ered by the brake lining and cause noise and chatter
when the brakes are applied.
Excessive wear and scoring of the rotor can cause
temporary improper lining contact if ridges are not
removed before installation of new brake pad assem-
blies.
Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock back. This will
increase guide pin sleeve wear due to tendency of cal-
iper to follow rotor wobble.
Thickness variation in a rotor can also result in
pedal pulsation, chatter and surge due to variation in
brake output. This can also be caused by excessive
runout in rotor or hub.
Dishing or distortion can be caused by extreme
heat and abuse of the brakes.
ROTOR RUNOUT AND THICKNESS VARIATION
On vehicle rotor runout is the combination of the
individual runout of the hub face and the runout ofthe rotor. (The hub and rotor runouts are separable).
To measure runout on the vehicle, remove the wheel
and reinstall the lug nuts tightening the rotor to the
hub. Mount Dial Indicator, Special Tool C-3339 with
Mounting Adaptor, Special Tool SP- 1910 on steering
arm. Dial indicator plunger should contact braking
surface of rotor approximately one inch from edge of
rotor (Fig. 19). Check lateral runout (both sides of
rotor) runout should not exceed 0.13 mm (0.005
inch).
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing rotor
from hub, make a chalk mark across both the rotor
and one wheel stud on the high side of runout so
you'll know exactly how the rotor and hub was orig-
inally mounted (Fig. 20). Remove rotor from hub.
Install Dial Indicator, Special Tool C-3339 and
Mounting Adaptor, Special Tool SP-1910 on steering
knuckle. Position stem so it contacts hub face near
Fig. 19 Checking Rotor For Runout
Fig. 20 Marking Rotor and Wheel Stud
5 - 14 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

(5) Remove master cylinder from vise.
NOTE: Note: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der. But the master cylinder must have been bled
and filled upon installation.
BRAKE ROTOR MACHINING
BRAKE ROTOR MACHINING PROCEDURES
Any servicing of the rotor requires extreme care to
maintain the rotor to within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or pulsation,
the rotor should be resurfaced, refaced (Fig. 41) or
(Fig. 42) or replaced.
The following chart shows the location of measure-
ments and specifications when servicing the rotor.
NOTE: All rotors have markings for minimum
allowable thickness cast on an un-machined sur-
face of the rotor (Fig. 43).
This marking includes 0.76 mm (0.030 inch) allow-
able rotor wear beyond the recommended 0.76 mm
(0.030 inch) of rotor refacing.
The collets, shafts and adapters used on the brake
lathe and the bearing cups in the rotor MUST be
clean and free from any chips or contamination.
When mounting the rotor on the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
If the rotor is not mounted properly, the lateral
runout will be worse after refacing or resurfacing
than before.REFACING BRAKE ROTOR
Refacing of the rotor is not required each time the
brake pads are replaced.
When refacing a rotor the required 0.8 mm (0.003
inch) TIR (Total Indicator Reading) and 0.013 mm
(0.0005 inch) thickness variation limits MUST BE
MAINTAINED.Extreme carein the operation of
rotor turning equipment is required.
Fig. 40 Bleeding Master Cylinder
Fig. 41 Refacing Brake Rotor
Fig. 42 Resurfacing Brake Rotor (Final Finish)
5 - 22 BRAKESPL
SERVICE PROCEDURES (Continued)

The use of a double straddle cutter (Fig. 41) that
machines both sides of the rotor at the same time is
highly recommended.
RESURFACNG BRAKE ROTOR
This operation can be used when rotor surface is
rusty, has lining deposits or excessive lateral runout
or thickness variation is evident.
A sanding rotor attachment will remove surface
contamination without removing much rotor mate-
rial.
It will generally follow variations in thickness that
are in the rotor.
BRAKE DRUM MACHINING
Measure drum runout and diameter. If not to spec-
ification, reface drum. (Runout should not exceed
0.1524 mm or 0.006 inch). The diameter variation
(oval shape) of the drum braking surface must not
exceed either 0.0635 mm (0.0025 inch) in 30É or
0.0889 mm (0.0035 inch) in 360É.All brake drums are marked with the maximum
allowable brake drum diameter (Fig. 44).
PARK BRAKE LEVER AUTO ADJUSTER
MECHANISM
WARNING: THE AUTO ADJUSTING FEATURE OF
THIS PARKING BRAKE LEVER CONTAINS A CLOCK
SPRING LOADED TO APPROXIMATELY 20 POUNDS.
DO NOT RELEASE THE AUTO ADJUSTER LOCK-
OUT DEVICE BEFORE INSTALLING CABLES INTO
THE EQUALIZER. KEEP HANDS OUT OF AUTO
ADJUSTER SECTOR AND PAWL AREA. FAILURE TO
OBSERVE CAUTION IN HANDLING THIS MECHA-
NISM COULD LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARK BRAKE
LEVER OR CABLES IS REQUIRED, THE AUTO
ADJUSTER MUST BE RELOADED AND LOCKED
OUT.
Fig. 43 Minimum Brake Rotor Thickness Markings
(Typical)
BRAKE ROTOR REFINISHING LIMITS
Braking RotorRotor
ThicknessMinimum
Rotor
ThicknessRotor
Thickness
VariationRotor Run
Out*Rotor Micro
Finish
All Front Disc Brakes 20.13-19.87
mm
.792 -.782
in.18.4 mm
.724 in.0.013 mm
0.0005 in.0.13 mm
0.005 in.15-80 RMS
All Rear Disc Brakes 9.25-8.75
mm.364
-.344 in.7.25 mm
.285 in.0.013 mm
0.0005 in.0.13 mm
0.005 in.15-80 RMS
*
TIR Total Indicator Reading (Measured On Vehicle)
Fig. 44 Brake Drum Maximum Diameter
Identification
PLBRAKES 5 - 23
SERVICE PROCEDURES (Continued)

BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)........ 1
CHARGING TIME REQUIRED............... 1
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR........ 2
BATTERY IGNITION OFF DRAW (IOD)........ 3
BATTERY LOAD TEST..................... 5
BATTERY OPEN CIRCUIT VOLTAGE TEST..... 6
BATTERY TEMPERATURE SENSOR.......... 6
SERVICE PROCEDURES
BATTERY CHARGING..................... 6CHARGING COMPLETELY DISCHARGED
BATTERY............................. 7
VISUAL INSPECTION..................... 7
REMOVAL AND INSTALLATION
BATTERY TRAY.......................... 9
BATTERY............................... 8
FRESH AIR INLET TUBE REMOVAL.......... 9
SPECIFICATIONS
BATTERY SPECIFICATIONS............... 10
TORQUE.............................. 10
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabilizes, and delivers electri-
cal current to operate various electrical systems in
the vehicle. The determination of whether a battery
is good or bad is made by its ability to accept a
charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid
in the electrolyte is measured as specific gravity
using a hydrometer. The original equipment (OE)
battery is equipped with a hydrometer (test indica-
tor) built into the battery cover. The specific gravity
indicates the battery's state-of-charge. The OE bat-
tery is sealed and water cannot be added.
The battery is vented to release gases that are cre-
ated when the battery is being charged and dis-
charged. The battery top, posts, and terminals should
be cleaned when other under hood maintenance is
performed.
When the electrolyte level is below the top of the
plates, Yellow/Clear in the test Indicator, the battery
must be replaced. The battery must be completely
charged, and the battery top, posts, and cable clampsmust be cleaned before diagnostic procedures are per-
formed.DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
A completely normal vehicle will have a small
amount of current drain on the battery with the key
out of the ignition. It can range from 4 to 10 milli-
amperes after all the modules time out. If a vehicle
will not be operated for approximately a 20 days, the
IOD fuse should be disconnected to minimize the
vehicle electrical drain on the battery. The IOD fuse
is located in the Power Distribution Center (PDC).
Refer to the PDC to locate the cover proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1ÉC (30ÉF) BATTERY. PER-
SONAL INJURY MAY RESULT.
The time required to charge a battery will vary
depending upon the following factors.
SIZE OF BATTERY
A completely discharged large heavy-duty battery
may require more recharging time than a completely
discharged small capacity battery. Refer to Battery
Charging Timetable for proper charging times.
PLBATTERY 8A - 1

exposure over the preceding several hours. If the bat-
tery has been charged or boosted a few minutes prior
to the test, the battery would be slightly warmer.
Refer to Battery Load Test Temperatures Table for
proper voltage/temperature reading:
(6) If battery passes load test, it is in good condi-
tion and further tests are not necessary. If it fails
load test, it should be replaced.
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a battery
has open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 7). Rotate the load control knob of theCarbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 8).
(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 10).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity. Refer to Battery Open Circuit
Voltage Table.
BATTERY TEMPERATURE SENSOR
For Battery Temperature Sensor refer to Group 8C
Generator.
SERVICE PROCEDURES
BATTERY CHARGING
A battery is considered fully charged when it will
meet all the following requirements.
²It has an open circuit voltage charge of at least
12.4 volts.
²It passes the 15 second load test. Refer to Bat-
tery Load Test.
²The built in test indicator dot is GREEN (Fig.
1).
NOTE: The battery cannot be refilled with water, it
must be replaced.
Fig. 9 Load 50% Cold Crank Rating
BATTERY LOAD TEST TEMPERATURES
Minimum
VoltageTemperature
ÉF ÉC
9.6 volts 70É and above 21É and above
9.5 volts 60É 16É
9.4 volts 50É 10É
9.3 volts 40É 4É
9.1 volts 30É -1É
8.9 volts 20É -7É
8.7 volts 10É -12É
8.5 volts 0É -18É
Fig. 10 Testing Open Circuit Voltage
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
8A - 6 BATTERYPL
DIAGNOSIS AND TESTING (Continued)

WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first, before charging battery to avoid damage to
electrical systems. Lift the red battery boot cover
from the positive cable clamp. Do not exceed 16.0
volts while charging battery. Refer to the instruc-
tions supplied with charging equipment
Battery electrolyte may bubble inside of battery
case while being charged properly. If the electrolyte
boils violently, or is discharged from the vent holes
while charging, immediately reduce charging rate or
turn off charger. Evaluate battery condition. Battery
damage may occur if charging is excessive.
Some battery chargers are equipped with polarity
sensing devices to protect the charger or battery from
being damaged if improperly connected. If the bat-
tery state of charge is too low for the polarity sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operating instructions provided
with battery charger being used.
CAUTION: Charge battery until test indicator
appears green. Do not overcharge.
It may be necessary to jiggle the battery or vehicle
to bring the green dot in the test indicator into view.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine cranking
capacity. Refer to Battery Load Test in this Group. If
the battery passes the load test, the battery is OK to
use. If battery will not pass the load test, it must be
replaced. Properly clean and inspect battery hold
downs, tray, terminals, cables, posts, and top before
completing service.
CHARGING COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless procedure is
properly followed, a good battery may be needlessly
replaced. Refer to Battery Charging Rate Table for
proper charging time.(1) Measure the voltage at battery posts with a
voltmeter accurate to 1/10 volt (Fig. 11). If below 10
volts, charge current will be low, and it could take
some time before it accepts a current in excess of a
few milliamperes. Such low current may not be
detectable on amp meters built into many chargers.
(2) Connect charger leads. Some chargers feature
polarity protection circuitry that prevents operation
unless charger is connected to battery posts correctly.
A completely discharged battery may not have
enough voltage to activate this circuitry. This may
happen even though the leads are connected properly.
(3) Battery chargers vary in the amount of voltage
and current they provide. For the time required for
the battery to accept measurable charger current at
various voltages, refer to the Battery Charging Rate
table. If charge current is still not measurable after
charging times, the battery should be replaced. If
charge current is measurable during charging time,
the battery may be good, and charging should be
completed in the normal manner.
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to
enter vent holes, as damage to battery can result.
(1) Clean top of battery with a solution of warm
water and baking soda.
(2) Apply soda solution with a bristle brush and
allow to soak until acid deposits loosen (Fig. 12).
BATTERY CHARGING RATE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
Fig. 11 Voltmeter Accurate to 1/10 Volt (Connected)
PLBATTERY 8A - 7
SERVICE PROCEDURES (Continued)

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
DOME LAMP............................ 1
ELECTRONIC DIGITAL CLOCK.............. 1
INSTRUMENT CLUSTER................... 2
WARNING AND INDICATOR LAMPS......... 2
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM............... 2
BRAKE SYSTEM WARNING LAMP TEST...... 2
FOG LAMP SWITCH TEST................. 2
FUEL TANK SENDING UNIT TEST........... 3
HEADLAMP SWITCH TEST................. 3
HEATER A/C BLOWER SWITCH TEST........ 3
HEATER BLOWER SWITCH TEST............ 3
INDIVIDUAL GAUGE INOPERATIVE.......... 4
INSTRUMENT PANEL AND COMPONENTS.... 4
LOW OIL PRESSURE WARNING LAMP TEST . . 4
MULTIPLE GAUGE INOPERATIVE TEST....... 4
SEAT BELT REMINDER SYSTEM TEST....... 6
SENDING UNIT......................... 6
SERVICE ENGINE SOON INDICATOR......... 6
VEHICLE SPEED SENSOR TEST............. 6
REMOVAL AND INSTALLATION
ASH RECEIVER RETAINER AND LAMP....... 6
CENTER BEZEL.......................... 6
CIGAR LIGHTER RECEPTACLE.............. 6
CLUSTER LAMP......................... 7
CLUSTER PRINTED CIRCUIT BOARD........ 7CLUSTER.............................. 7
DOME LENS/LAMP....................... 8
FLOOR CONSOLE........................ 8
GAUGE................................ 8
GLOVE BOX DOOR/BIN................... 8
GLOVE BOX SWITCH/LAMP................ 9
HEADLAMP SWITCH..................... 9
HEATER A/C CONTROL BLOWER SWITCH . . . 10
HEATER A/C CONTROL LAMP............ 10
HEATER A/C CONTROL................... 9
HEATER CONTROL BLOWER SWITCH....... 10
IGNITION KEY LAMP.................... 10
INSTRUMENT PANEL.................... 10
LEFT TRIM PANEL...................... 10
ODOMETER............................ 10
RADIO................................ 12
REAR WINDOW DEFOGGER AND/OR FOG
LAMP SWITCH....................... 12
RIGHT TRIM PANEL..................... 12
SHIFTER KNOB......................... 13
STEERING COLUMN COVER LINER......... 13
STEERING COLUMN COVER.............. 13
STEERING COLUMN SHROUDS............ 13
TOP COVER AND CLUSTER BEZEL
REMOVAL........................... 14
TRANSMISSION RANGE INDICATOR LAMP . . 14
TRUNK LAMP/LENS..................... 14
VEHICLE SPEED SENSOR................ 14
GENERAL INFORMATION
INTRODUCTION
The purpose of the dash gauges and indicator
lamps is to keep the driver informed about the oper-
ating condition of the vehicle. If an abnormal condi-
tion occurs, the driver is informed by indicator lamp.
The driver can seek service before damage occurs.
Indicator lamps use ON/OFF switch functions for
operation, while gauges use a sending unit or sensor.
DESCRIPTION AND OPERATION
DOME LAMP
The Dome Lamp operates when a door is open or
when the headlamp switch is placed in courtesy posi-
tion.
ELECTRONIC DIGITAL CLOCK
The electronic digital clock is in the radio. The
clock and radio each use the display panel built into
the radio. A digital readout indicates the time in
hours and minutes whenever the ignition switch is in
the ON or ACC position.
PLINSTRUMENT PANEL AND SYSTEMS 8E - 1