2000 DODGE NEON Service Repair Manual

INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the three module
retaining nuts to 22 to 34 N´m (200 to 300 in. lbs.)
torque. Do not connect battery negative cable. Refer
to Diagnosis and Testing for Airbag System Test pro-
cedures.
DEPLOYED MODULE
REMOVAL
When removing a deployed module, rubber gloves,
eye protection, and a long-sleeved shirt should be
worn, as there may be deposits on the surface which
could irritate the skin and eyes.
(1) Roll/fold airbag towards instrument panel.
(2) Close door over folded airbag and tape door
closed.
(3) Disconnect and isolate the battery negative
cable (Fig. 4).
(4) Remove instrument panel top cover. Refer to
Group 8E Instrument Panel Systems, Instrument
Panel Top Cover Removal and Installation.
(5) Remove three screws to glove box door and
remove door from instrument panel.
(6) Remove three passenger airbag cover screws
attaching cover to top of instrument panel (Fig. 9).
(7) Remove two passenger airbag cover screws
attaching cover to front lower instrument panel.
(8) Remove three module attaching nuts from the
support structure.
(9) Lift module up until the wire connector is visi-
ble and disconnect the 4-way wire connector from
module. Unlock the red locking tab and compress
lock to release the connector (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
Ensure that the red locking tab is in the lock position
after installing the connector. Tighten trim screws to
2 N´m (20 in. lbs.) torque. Tighten the module nuts to
22 to 34 N´m (200 to 300 in. lbs.) torque. Do not con-
nect battery negative cable. Refer to Diagnosis and
Testing for Airbag System Test procedures.
STEERING WHEEL
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 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
REMOVAL
(1) Adjust the steering wheel so that the tires are
in the straight ahead position. Then:
(a) Rotate the steering wheel half turn (180
degrees) to the right (clockwise).
(b) Lock column with the ignition cylinder lock.
(2) Disconnect and isolate the battery negative
cable (Fig. 4).
(3) Remove the speed control switches and discon-
nect the wire connectors or covers (Fig. 11).
(4) Remove the Driver Airbag Module attaching
bolts from the back of steering wheel.
(5) Lift module and disconnect the airbag and horn
wire connectors.
(6) Remove steering wheel retaining nut.
(7) Remove the steering wheel with a steering
wheel puller (Fig. 12). While removing the steering
wheel take care to feed the wires gently through the
holes in the steering wheel.
INSTALLATION
(1) Confirm that:
(a) The steering wheel position is a half turn
(180 degrees) to the right (clockwise).
(b) The column is locked with the ignition cylin-
der lock.
(c) Check that the turn signal stalk is in the
neutral position.
(2) Install the steering wheel ensuring the flats on
hub align with the clockspring. Pull the horn lead,
airbag and speed control leads through the larger
Fig. 11 Steering Wheel Remove/Install
8M - 8 PASSIVE RESTRAINT SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

slot. Ensure leads do not get pinched under the steer-
ing wheel.
(3) Install the steering wheel retaining nut, and
tighten it to 61 N´m (45 ft. lbs.) torque.
(4) Install the driver airbag module. Refer to
Driver Airbag Module Removal and Installation in
this section.
(5) Do not connect the battery negative cable.
Refer to Diagnosis and Testing for Airbag System
Test procedures.
ADJUSTMENTS
CLOCKSPRING CENTERING PROCEDURE
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE BEFORE
BEGINNING ANY AIRBAG SYSTEM COMPONENTREMOVAL 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 1 MINUTE BEFORE REMOVING ANY AIRBAG
COMPONENTS.
If the rotating tape within the clockspring is not
positioned properly with the steering wheel and the
front wheels, the clockspring may fail during use.
The following procedureMUST BE USEDto center
the clockspring if:
²The clockspring is not known to be properly
positioned.
²The front wheels were moved.
²The steering wheel was moved from the half
turn (180 degrees) to the right (clockwise) position.
(1) Remove clockspring. Refer to Clockspring
Removal and Installation in this section.
(2) Rotate the clockspring rotor in the CLOCK-
WISE DIRECTION to the end of travel. Do not apply
excessive torque.
(3) From the end of travel, rotate the rotor three
full turns in the counterclockwise direction. The horn
wire and the squib wire should end up at the bottom.
If not, rotate the rotor counter clockwise until the
wires are properly orientated, but not more than half
turn (180 degrees). Engage clockspring locking mech-
anism.
(4) For installation, refer to Clockspring Removal
and Installation in this section.
(5) Do not connect battery negative cable. Refer to
Diagnosis and Testing for Airbag System Test
procedures.
Fig. 12 Steering Wheel Puller Installed
1 ± STEERING WHEEL
2 ± STEERING WHEEL PULLER
PLPASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)

ELECTRICALLY HEATED SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER SYSTEM.........1
REAR WINDOW DEFOGGER SWITCH.........1
DIAGNOSIS AND TESTING
GRID LINES.............................2
REAR WINDOW DEFOGGER SWITCH.........2REAR WINDOW DEFOGGER SYSTEM.........2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR..........3
REMOVAL AND INSTALLATION
REAR WINDOW DEFOGGER SWITCH.........4
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER SYSTEM
For proper operation of the Rear Window Defogger
system refer to the Owner's Manual.
The system consists of a rear glass with two verti-
cal bus bars and a series of electrically connected
grid lines fired on the inside surface (Fig. 1). A con-
trol switch and a timing circuit are combined into a
single assembly.
Circuit protection is provided by a cartridge fuse
located in the Power Distribution Center (PDC) for
the heated grid circuit, and by a fuse in the fuse
block for the control circuit.
When the switch is turned to the ON position, cur-
rent is directed to the rear defogger grid lines. The
heated grid lines heat the rear glass to clear the sur-
face of fog or frost.CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch is a control
switch and timing circuit integrated into a single
panel mounted assembly (Fig. 2). Actuating the
switch energizes the circuit which allows current to
flow through the grid lines. Upon initial actuation for
approximately eight to ten minutes, or until either
the switch or ignition is turned off. An indicating
lamp illuminates a Light Emitting Diode (LED)
inlaid in the control switch.
Fig. 1 Rear Window Defogger - Typical
1 ± REAR WINDOW DEFOGGER
Fig. 2 Rear Window Defogger Switch Location
1 ± REAR WINDOW DEFOGGER SWITCH
2 ± TRACTION CONTROL SWITCH
3 ± CIGAR LIGHTER/AUXILIARY POWER OUTLET
PLELECTRICALLY HEATED SYSTEMS 8N - 1

DIAGNOSIS AND TESTING
GRID LINES
The horizontal grid lines and vertical bus bar lines
printed and fired on the inside surface of rear win-
dow glass (Fig. 5) comprise an electrical parallel cir-
cuit. The electrically conductive lines are composed of
a silver-ceramic material which when fired on glass
becomes bonded to the glass and is highly resistant
to abrasion. It is possible however, that a break may
occur in an individual grid line resulting in no cur-
rent flow through the line. To detect breaks in grid
lines the following procedure is required:
(1) Turn ignition ON and turn control switch to
ON. The LED should come on.
(2) Using a DC voltmeter with 0-15 volt range,
contact terminal (B) with the negative lead of the
voltmeter. With the positive lead of the voltmeter,
contact terminal (A) (Fig. 5). The voltmeter should
read 10-14 volts. A lower voltage reading indicates a
poor connection in the feed or the ground circuit.
(3) With the negative lead of the voltmeter, contact
a good body ground point. The voltage reading should
not change.
(4) Connect the negative lead of the voltmeter to
terminal (B) and touch each grid line at Mid-Point
with the positive lead. A reading of:
²Approximately 6 volts indicates the line is OK.
²0 volts indicates a break in line between Mid-
Point (C) and terminal (A).
²10-14 volts indicates a break between Mid-Point
(C) and terminal (B).
Move the lead toward the break and voltage will
change as soon as the break is crossed. Refer to (Fig.
5).
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch may be tested in
the vehicle or out of the vehicle, on the bench.
IN-VEHICLE TESTING
(1) Remove the switch from the instrument panel
but leave the switch connected, refer to Group 8E-In-
strument Panel and Systems, Auxiliary Switch Bezel
Removal and Installation.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, check for battery voltage at
Pin 1 and 2 (Fig. 3).
(a) If OK, go to Step 4.
(b) If NOT OK, check fuse 7 in the fuse block
and the 40 Amp cartridge fuse in the Power Distri-
bution Center (PDC). If fuses are OK, check wiring
circuit. Refer to Group 8W-Wiring Diagrams.
(4) Check Pin 5, with switch in the ON position
there should be battery voltage and no voltage in the
OFF position.(a) If OK, go to Step 5.
(b) If NOT OK, no voltage in the ON position or
voltage in the OFF position. Replace the switch.
(5) Press switch to ON position. The indicator
lamp should come on and remain on for approxi-
mately 10 minutes. If the indicator lamp fails to light
or no voltage is present for approximately 10 min-
utes. Replace Rear Window Defogger Switch. Refer to
Group 8E-Instrument Panel and Systems, Auxiliary
Switch Bezel Removal and Installation.
BENCH TESTING
(1) First remove switch. Refer to Group 8E-Instru-
ment Panel and Systems, Auxiliary Switch Bezel
Removal and Installation.
(2) With switch removed from vehicle, use a
jumper wire and connect a 12 volt supply to Pin 1
and 2. Using a third jumper wire, ground Pin 3.
Refer to (Fig. 4) and the Rear Window Defogger
Switch and Harness Connector Pin Call-Outs table.
(3) Follow the same procedures used for IN-VEHI-
CLE TESTING, except for step Step 2.
REAR WINDOW DEFOGGER SYSTEM
Electrically heated rear window defogger operation
can be checked in the vehicle in the following man-
ner:
(1) Turn the ignition switch to the ON position.
Fig. 3 Rear Window Defogger Switch Harness
Connector
REAR WINDOW DEFOGGER SWITCH AND
HARNESS CONNECTOR PIN CALL-OUTS
PIN FUNCTION
1 FUSED B+
2 FUSED IGNITION SWITCH OUTPUT
(RUN)
3 GROUND
4 PANEL LAMPS DRIVER
5 PANEL LAMPS DRIVER
8N - 2 ELECTRICALLY HEATED SYSTEMSPL

(2) Connect an ammeter in series with the battery.
Push the rear window defogger switch to the ON
position (Fig. 2). A distinct increase in amperage
draw should be noted.
(3) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected in three to four minutes
of operation.
(4) Using a DC voltmeter, connect the negative
lead to Point B, and the positive lead to Point A (Fig.
5). The voltmeter should read 10-14 volts.(5) Step 2, Step 3 or Step 4 above will confirm sys-
tem operation. Indicator light illumination means
that there is power available at the switch output,
and does not necessarily verify system operation.
(6) If turning the switch ON produced no distinct
current draw on the ammeter the problem should be
isolated in the following manner:
(a) Confirm the ignition switch is ON.
(b) Ensure that the heated rear glass feed wire
is connected to the terminal or pigtail and that the
ground wire is in fact grounded.
(c) Ensure that the cartridge fuse and control
circuit fuse are OK and all electrical connections
are secure.
(7) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing is defective:
(a) Rear Window Defogger Switch.
(b) All rear window grid lines would have to be
broken or one of the feed wires are not connected
for the system to be inoperative.
(8) If turning the switch ON produces severe volt-
meter deflection, the circuit should be closely checked
for a shorting condition.
(9) If the system operation has been verified but
indicator lamp does not light, replace the switch.
(10) For detailed wiring information, refer to group
8W-Wiring Diagrams.
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING; CALL A PHYSICIAN
IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH
WITH PLENTY OF WATER. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR FLAME.
CONTENTS CONTAIN 3 PERCENT FLAMMABLE
SOLVENTS.
KEEP OUT OF REACH OF CHILDREN.
The repair of the grid lines or the terminal is pos-
sible using the MopartRepair Package or equiva-
lent.
Fig. 4 Rear Window Defogger Switch Connector
Fig. 5 Rear Glass Grid Line Test - Typical
1 ± REAR WINDOW DEFOGGER
2 ± BUS BARS
3 ± VOLTAGE FEED ªAº
4 ± VOLTMETER
5 ± PICK-UP LEADS
6 ± C. H. M. S. L. TRIM COVER
7 ± PARCEL SHELF
8 ± GROUND ªBº
9 ± MID-POINT ªCº
PLELECTRICALLY HEATED SYSTEMS 8N - 3
DIAGNOSIS AND TESTING (Continued)

(1) Mask repair area so conductive epoxy can be
extended onto the line or the bus bar (Fig. 6).
(2) Follow instructions in repair kit for preparing
damaged area.
(3) Remove package separator clamp and mix plas-
tic conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy.
(4) For grid line, mark off area to be repaired with
masking tape or a template (Fig. 6).(5) Apply conductive epoxy through slit in masking
tape. Overlap both ends of the break by 19 mm (3/4
inch).
(6) For a terminal or pigtail replacement, mask
adjacent areas so epoxy can be extended onto line as
well as bus bar. Apply a thin layer of epoxy to area
where terminal was fastened and to adjacent line.
(7) Apply a thin layer of conductive epoxy on ter-
minal and place terminal on desired location. To pre-
vent terminal from moving while the epoxy is curing,
it must be wedged or clamped.
(8) Carefully remove masking tape from grid line.
CAUTION: Do not allow the glass surface to exceed
204ÉC (400ÉF), glass may fracture.
(9) Allow epoxy to cure 24 hours at room tempera-
ture or use heat gun with a 260Éto 371ÉC (500É to
700ÉF) range for 15 minutes. Hold gun approximately
254 mm (10 inches) from repaired area.
(10) After conductive epoxy is properly cured
remove wedge from terminal and check out operation
of rear window defogger. Do not attach connectors
until curing is complete.
REMOVAL AND INSTALLATION
REAR WINDOW DEFOGGER SWITCH
Refer to Group 8E-Instrument Panel and Systems,
Auxiliary Switch Bezel Removal and Installation for
rear defogger switch service procedures.
Fig. 6 Grid Line Repair
1 ± BREAK
2 ± GRID LINE
3 ± MASKING TAPE
8N - 4 ELECTRICALLY HEATED SYSTEMSPL
SERVICE PROCEDURES (Continued)

POWER DISTRIBUTION SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER DISTRIBUTION SYSTEM.............1
POWER DISTRIBUTION CENTER (PDC).......1
FUSE BLOCK.............................2REMOVAL AND INSTALLATION
FUSE BLOCK.............................2
POWER DISTRIBUTION CENTER (PDC).......2
DESCRIPTION AND OPERATION
POWER DISTRIBUTION SYSTEM
This group covers the various standard and
optional power distribution components used on this
model. Refer to the Component Index of Group 8W -
Wiring Diagrams for complete circuit diagrams of the
various power distribution components.
The power distribution system for this vehicle is
designed to provide safe, reliable, centralized and
convenient to access distribution of the electrical cur-
rent required to operate all of the many standard
and optional factory-installed electrical and electronic
powertrain, chassis, safety, comfort and convenience
systems. At the same time, these systems were
designed to provide centralized locations for conduct-
ing diagnosis of faulty circuits, and for sourcing the
additional current requirements of many aftermarket
vehicle accessory and convenience items.
These power distribution systems also incorporate
various types of circuit control and protection fea-
tures, including:
²Fuses
²Fuse cartridges
²Fusible links
²Automatic resetting circuit breakers
²Relays
²Flashers
²Timers
²Circuit splice blocks.
The power distribution system for this vehicle con-
sists of the following components:
²Power Distribution Center (PDC)
²Fuse Block
Following are general descriptions of the major
components in the power distribution system. Refer
to the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the power distribution system components.
POWER DISTRIBUTION CENTER (PDC)
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-ment Power Distribution Center (PDC). The molded
plastic PDC housing is located in the left front corner
of the engine compartment, just behind the air
cleaner housing and left of the battery (Fig. 1). The
PDC housing has a molded plastic cover. The PDC
cover is easily removed for service access and has a
convenient fuse and relay layout label affixed to the
inside surface of the cover to ensure proper compo-
nent identification.
The PDC housing is secured to the left inner
fender well an indexing pin and one screw. All of the
PDC outputs are through the integral engine com-
partment wire harness.
All of the current from the generator cable connec-
tion goes to the battery through a 140 ampere fusible
link that is secured with a nut to the positive battery
cable terminal. The PDC houses up to ten six fuse
cartridges, which replace all in-line fusible links. The
PDC also houses up to twelve blade-type fuses, up to
three full International Standards Organization
(ISO) relays, and up to eight mini International
Standards Organization (ISO) relays. Internal con-
nection of all the PDC circuits is accomplished by an
intricate network of hard wiring and bus bars. Refer
toPower Distributionin the Component Index of
Group 8W - Wiring Diagrams for complete circuit
diagrams.
Fig. 1 Power Distribution Center (PDC) Location
PLPOWER DISTRIBUTION SYSTEMS 8O - 1