2000 DODGE NEON relay

STARTER RELAY PIN CALL-OUT
PIN CIRCUIT COLOR DESCRIPTION
1 (86) A041 YL IGNITION SWITCH OUTPUT (START)
2 (85) K090 TN PCM
3 (30) A001 RD FUSED B+
4 (87A) NOT USED
5 (87) T040 BR STARTER SOLENOID
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the START position. On
vehicles with a manual transmission, the clutch
pedal must be fully depressed for this test. Check for
battery voltage at the cavity for relay terminal 86
with the ignition switch in the START position, and
no voltage when the ignition switch is released to the
ON position. If OK, go to Step 5. If not OK with an
automatic transmission, check for an open or short
circuit to the ignition switch and repair, if required.
If the circuit to the ignition switch is OK, see the
Ignition Switch Test procedure in this group. If not
OK with a manual transmission, check the circuit
between the relay and the clutch interlock/upstop
switch for an open or a short circuit. If the circuit is
OK, refer to the Clutch Interlock/Upstop Switch
Diagnosis and Testing in Group 6-Clutch.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the PCM only when the gearshift selector
lever is in the Park or Neutral positions. On vehicles
with a manual transmission, it is grounded through
the PCM when the clutch pedal is depressed. Check
for continuity to ground at the cavity for relay termi-
nal 85. If not OK, check for an open or short circuit
to the park/neutral starting and back-up lamp
switch, or the clutch interlock/upstop switch. Repair,
as necessary. If the circuit is OK, refer to the Park/Neutral Starting and Back-Up Lamp Switch Removal
and Installation in Group 21-Transaxle. Testing is
located within the Removal and Installation proce-
dures.
SAFETY SWITCHES
For diagnosis of:
²Clutch Interlock/Upstop Switch, refer to Diagno-
sis and Testing in Group 6-Clutch.
²Park/Neutral Starting and Back-Up Lamp
Switch, refer to Removal and Installation in Group
21-Transaxle. Testing is located within the Removal
and Installation procedures.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Check all wiring for opens or
shorts, and all connectors for being loose or corroded.
Refer to Group 8D-Ignition Systems, or Group
8W-Wiring Diagrams.
BATTERY
Refer to Group 8A-Battery for Diagnosis and Test-
ing of the battery.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W-Wiring Diagrams.
FEED CIRCUIT RESISTANCE
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown (ASD) Relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
PLSTARTING SYSTEMS 8B - 3
DIAGNOSIS AND TESTING (Continued)

FEED CIRCUIT
The following procedure will require a suitable
volt-ampere tester (Fig. 8).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 9). Refer to the operating instructions
provided with the tester being used.(2) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown (ASD) Relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
position or with the clutch pedal depressed and SET
parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
8).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²If voltage is below 9.6 volts and amperage draw
is above 300 amps, the problem is the starter.
Replace the starter. Refer to Starter Removal and
Installation in this section.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect the ASD relay. Start the vehi-
cle several times to assure the problem has been cor-
rected.
Fig. 7 Battery Positive Cable Resistance
1 ± VOLTMETER
Fig. 8 Volt Ampere Tester - Typical
Fig. 9 Volt-Ampere Tester Connections - Typical
1 ± POSITIVE CLAMP
2 ± NEGATIVE CLAMP
3 ± INDUCTION AMMETER CLAMP
PLSTARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM
For circuit descriptions and diagrams, refer to
8W-21, Starting System in Group 8W-Wiring Dia-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Group 8A-Battery
for more information.²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Clutch Interlock/Upstop Switch- Visually
inspect the clutch interlock/upstop switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Park/Neutral Starting and Back-Up Lamp
Switch- Visually inspect the park/neutral starting
and back-up lamp switch for indications of physical
damage and loose or corroded wire harness connec-
tions.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
²Starter Motor- Visually inspect the starter
motorfor indications of physical damage and loose or
corroded wire harness connections.
²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
8B - 6 STARTING SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE.1. BATTERY
DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT
WIRING FAULTY.
3. STARTER RELAY
FAULTY.
4. IGNITION SWITCH
FAULTY.
5. PARK/NEUTRAL
STARTING AND
BACK-UP LAMP
SWITCH (AUTO TRANS)
FAULTY OR MIS-
ADJUSTED.
6. CLUTCH
INTERLOCK/UPSTOP
SWITCH (MAN TRANS)
FAULTY.
7. STARTER SOLENOID
FAULTY.
8. STARTER ASSEMBLY
FAULTY.1. REFER TO GROUP 8A, BATTERY. CHARGE OR REPLACE
BATTERY, IF REQUIRED.
2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. REFER TO IGNITION SWITCH TEST, IN GROUP 8D-
IGNITION SYSTEM OR GROUP 8W-WIRING DIAGRAMS.
REPLACE SWITCH, IF NECESSARY.
5. REFER PARK/NEUTRAL STARTING AND BACK-UP LAMP
SWITCH TEST IN GROUP 21-TRANSAXLE. REPLACE SWITCH,
IF NECESSARY.
6. REFER TO CLUTCH INTERLOCK/UPSTOP SWITCH TEST,
IN GROUP 6-CLUTCH (LOCATED WITHIN THE SWITCH
REMOVAL AND INSTALLATION). REPLACE SWITCH, IF
NECESSARY.
7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.1. BATTERY
DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT
WIRING FAULTY.
3. STARTER ASSEMBLY
FAULTY.
4. ENGINE SEIZED.1. REFER TO GROUP 8A, BATTERY. CHARGE OR REPLACE
BATTERY AS NECESSARY.
2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. REFER TO GROUP 9-ENGINE, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.
2. STARTER ASSEMBLY
FAULTY.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.
2. STARTER RELAY
FAULTY.
3. IGNITION SWITCH
FAULTY.
4. STARTER ASSEMBLY
FAULTY.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. REFER TO IGNITION SWITCH TEST, IN GROUP 8D-
IGNITION SYSTEM. REPLACE SWITCH, IF NECESSARY.
4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
PLSTARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
SAFETY SWITCHES
For Removal and Installation of:
²Clutch Interlock/Upstop Switch, refer to
Removal and Installation in Group 6-Clutch.
²Park/Neutral Starting and Back-Up Lamp
Switch, refer to Removal and Installation in Group
21-Transaxle.
STARTER MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 10).
(2) Raise vehicle on hoist.
(3) Remove starter bolts (Fig. 11).
(4) Remove starter assembly.
(5) Disengage latch and remove solenoid connector
from starter assembly.
(6) Remove battery positive connector from starter
assembly. It is not necessary to remove the alternator
output lead from the connector.
INSTALLATION
(1) Clean corrosion/dirt from the cable and wire
terminals before installing wiring to the solenoid.
(2) Attach battery positive connector to starter.
Ensure alternator output connector is snapped into
the battery positive connector. Tighten the captive
nut to 10 N´m (90 in. lbs.).
CAUTION: It is critical that the alternator output ter-
minal be connected to the battery positive terminal
of the starter solenoid, for proper operation of the
charging and cranking systems.
(3) Install solenoid connector to starter. Ensure
that latch is fully engaged.
(4) Position the starter face into transmission
housing. Start bottom mounting bolt and thread in
until bolt is snug.
(5) Attach ground cable to upper starter mounting
bolt.
(6) Ensure the proper starter alignment before
tightening the starter mounting bolts to 54 N´m (40
ft. lbs.) torque.
(7) Lower vehicle and connect negative battery
cable.
STARTER RELAY
The relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for relay location.
Fig. 10 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
Fig. 11 Starter Mounting/Location
1 ± NEGATIVE BATTERY CABLE
8B - 8 STARTING SYSTEMSPL

IGNITION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
IGNITION SYSTEM........................1
SPARK PLUGS...........................1
SPARK PLUG CABLES.....................1
ELECTRONIC IGNITION COILS...............2
AUTOMATIC SHUTDOWN RELAY.............2
CRANKSHAFT POSITION SENSORÐPCM
INPUT................................3
CAMSHAFT POSITION SENSORÐPCM
INPUT................................4
KNOCK SENSOR..........................5
IGNITION SWITCH........................5
LOCK KEY CYLINDER......................5
IGNITION INTERLOCK.....................6
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE....................6SPARK PLUG CABLE SERVICE..............6
IGNITION COIL...........................6
AUTOMATIC SHUTDOWN RELAY.............6
CAMSHAFT POSITION SENSOR..............6
CRANKSHAFT POSITION SENSOR............8
KNOCK SENSOR..........................8
IGNITION SWITCH........................8
LOCK KEY CYLINDER......................9
IGNITION INTERLOCK....................10
SPECIFICATIONS
VECI LABEL............................10
FIRING ORDERÐ2.0L....................10
TORQUE SPECIFICATION..................11
SPARK PLUG CABLE RESISTANCEÐSOHC....11
SPARK PLUG...........................11
IGNITION COIL..........................11
DESCRIPTION AND OPERATION
IGNITION SYSTEM
DESCRIPTION
The system's three main components are the coil
pack, crankshaft position sensor, and camshaft posi-
tion sensor.
OPERATION
Basic ignition timing is not adjustable.The
Powertrain Control Module (PCM) determines spark
advance. The 2.0L engines use a fixed ignition timing
system. The distributorless electronic ignition system
is referred to as the Direct Ignition System (DIS).
SPARK PLUGS
The 2.0L engines uses resistor spark plugs. For
spark plug identification and specifications, Refer to
the Specifications section at the end of this group.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. Aftercleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the
electrodes (Fig. 1) to the dimensions specified in the
chart at the end of this section by bending the
ground electrode (just above the attachment weld)
with the appropriate tool.
Never apply any force between the electrode or
damage to the center electrode assembly will result.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion and damage.
Tighten spark plugs to 28 N´m (20 ft. lbs.) torque.
SPARK PLUG CABLES
Spark plug cables are sometimes referred to as sec-
ondary ignition wires. The wires transfer electrical
current from the coil pack to individual spark plugs
at each cylinder. The resistor type, nonmetallic spark
plug cables provide suppression of radio frequency
emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil and spark plugs. Terminals should
be fully seated. The nipples and spark plug covers
should be in good condition. Nipples should fit tightly
on the coil. Spark plug boot should completely cover
the spark plug hole in the cylinder head cover. Install
the boot until the terminal snaps over the spark
plug. A snap must be felt to ensure the spark plug
cable terminal engaged the spark plug.
PLIGNITION SYSTEM 8D - 1

Loose cable connections will corrode, increase resis-
tance and permit water to enter the coil towers.
These conditions can cause ignition malfunction.
Plastic clips in various locations protect the cables
from damage. When the cables are replaced the clips
must be used to prevent damage to the cables, and
should be rotated about 30É below the horizontal.
ELECTRONIC IGNITION COILS
DESCRIPTION
The coil pack consists of 2 coils molded together.
The coil pack is mounted on the valve cover (Fig. 2).
OPERATION
WARNING: THE DIRECT IGNITION SYSTEM GEN-
ERATES APPROXIMATELY 40,000 VOLTS. PER-
SONAL INJURY COULD RESULT FROM CONTACT
WITH THIS SYSTEM.
High tension leads route to each cylinder from the
coil. The coil fires two spark plugs every power
stroke. One plug is the cylinder under compression,
the other cylinder fires on the exhaust stroke. Coil
number one fires cylinders 1 and 4. Coil number two
fires cylinders 2 and 3. The PCM determines which
of the coils to charge and fire at the correct time.
The Auto Shutdown (ASD) relay provides battery
voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When
the PCM breaks the contact, the energy in the coil
primary transfers to the secondary causing thespark. The PCM will de-energize the ASD relay if it
does not receive the crankshaft position sensor and
camshaft position sensor inputs. Refer to Auto Shut-
down (ASD) RelayÐPCM Output, in this section for
relay operation.
AUTOMATIC SHUTDOWN RELAY
DESCRIPTION
The ASD relay is located in the PDC (Fig. 3). The
inside top of the PDC cover has label showing relay
and fuse identification.
Fig. 1 Checking Spark Plug Electrode Gap
1 ± TAPER GAUGE
Fig. 2 Ignition Coil Pack
1 ± IGNITION COILS
2 ± SPARK PLUG CABLE
3 ± SPARK PLUG INSULATOR
Fig. 3 Power Distribution Center (PDC)
8D - 2 IGNITION SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

OPERATION
The Automatic Shutdown (ASD) relay supplies bat-
tery voltage to the fuel injectors, electronic ignition
coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC)
supplies voltage to the solenoid side and contact side
of the relay. The fuse also protects the power circuit
for the fuel pump relay and pump. The fuse is
located in the PDC. Refer to the Wiring Diagrams for
circuit information.
The PCM controls the ASD relay by switching the
ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the
ignition switch is in the Off position. When the igni-
tion switch is in On or Start, the PCM monitors the
crankshaft and camshaft position sensor signals to
determine engine speed and ignition timing (coil
dwell). If the PCM does not receive crankshaft and
camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the
ASD relay.
CRANKSHAFT POSITION SENSORÐPCM
INPUT
DESCRIPTION
The crankshaft position sensor mounts to the
engine block behind the generator, just above the oil
filter (Fig. 4).
The PCM uses the Crankshaft Position sensor to
calculate the following:
²Engine RPM²TDC number 1 and 4
²Ignition coil synchronization
²Injector synchronization
²Camshaft-to-crankshaft misalignment (Timing
belt skipped 1 tooth or more diagnostic trouble code).
OPERATION
The Crankshaft Position (CKP) sensor is a Hall-ef-
fect sensor. The second crankshaft counterweight has
two sets of four timing reference notches including a
60 degree signature notch (Fig. 5).
Fig. 5 Timing Reference Notches
1 ± MACHINED NOTCHES
2 ± CRANKSHAFT POSITION SENSOR
Fig. 4 Crankshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± OIL FILTER
3 ± GENERATOR
PLIGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)