2000 DODGE NEON Service Repair Manual

WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 2) is used to indicate this. When han-
dling any component with this symbol comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective
packing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: - Most of the electrical components used
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance rating. In addi-
tion, make sure the power is disconnected from the
circuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 3). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly check the following items.
Fig. 2 Electrostatic Discharge Symbol
Fig. 3 Probing Tool
1 ± SPECIAL TOOL 6801
2 ± PROBING END
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DESCRIPTION AND OPERATION (Continued)

²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully
seated into the connector/component and locked in
position
²Dirt or corrosion on the terminals. Any amount
of corrosion or dirt could cause an intermittent prob-
lem
²Damaged connector/component casing exposing
the item to dirt and moisture
²Wire insulation that has rubbed through causing
a short to ground
²Some or all of the wiring strands broken inside
of the insulation covering
²Wiring broken inside of the insulation.
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems in this section.
TESTING FOR VOLTAGE POTENTIAL
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 4).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the circuit being checked
or, disconnect the battery.(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 5).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
TESTING FOR A SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 6).
Fig. 4 Testing for Voltage Potential
Fig. 5 Testing for Continuity
1 ± FUSE REMOVED FROM CIRCUIT
PL8W - 01 GENERAL INFORMATION 8W - 01 - 9
DIAGNOSIS AND TESTING (Continued)

(2) Connect the other lead of the voltmeter to the
other side of the switch or component.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
SERVICE PROCEDURES
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gage be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1) (Fig. 7).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 7).
(6) Twist the wires together (example 3) (Fig. 7).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
Fig. 6 Testing for Voltage Drop
Fig. 7 Wire Repair
1 ± EXAMPLE 1
2 ± EXAMPLE 2
3 ± EXAMPLE 3
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DIAGNOSIS AND TESTING (Continued)

TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 8).
(4) Using special tool 6742 release the locking fin-
gers on the terminal (Fig. 9).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal, as
necessary.
TERMINAL/CONNECTOR REPAIRÐTHOMAS
AND BETTS CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 10).
(4) Insert the probe end of special tool 6934 into
the back of the connector cavity (Fig. 11).
(5) Grasp the wire and tool 6934 and slowly
remove the wire and terminal from the connector.
(6) Repair or replace the terminal.
Fig. 8 Molex Connector Repair
1 ± CONNECTOR
2 ± SPECIAL TOOL 6742
Fig. 9 Using Special Tool 6742
1 ± CONNECTOR
2 ± SPECIAL TOOL 6742
Fig. 10 Thomas and Betts Connector Lock Release
Tabs
1 ± LOCK TABS
Fig. 11 Removing Wire Terminal
1 ± SPECIAL TOOL 6934
PL8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)

(7) Install the wire and terminal in the connector.
Fully seat the terminal in the connector.
(8) Push in the single lock tab on the side of the
connector (Fig. 12).
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 13).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 14).(5) Repair or replace the connector or terminal as
necessary.
(6) When re-assembling the connector, the locking
wedge must be placed in the locked position to pre-
vent terminal push out.CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove the connector locking wedge, if
required (Fig. 15).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
Fig. 12 Single Lock Tab
1 ± SINGLE LOCK TAB
Fig. 13 Augat Connector Repair
1 ± LOCKING TAB
2 ± CONNECTOR
Fig. 14 Using Special Tool 6932
1 ± SPECIAL TOOL 6932
2 ± CONNECTOR
Fig. 15 Connector Locking Wedge
1 ± CONNECTOR
2 ± CONNECTOR LOCKING WEDGE TAB
8W - 01 - 12 8W - 01 GENERAL INFORMATIONPL
SERVICE PROCEDURES (Continued)

kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 16) (Fig. 17).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 18).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 18).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
Fig. 16 Terminal Removal
1 ± CONNECTOR
2 ± FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
1 ± FROM SPECIAL TOOL KIT 6680
2 ± CONNECTOR
PL8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)

(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).
(4) Position the connector locking finger away from
the terminal using the proper pick from special toolkit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires.
Fig. 18 Stagger Cutting Wires
1 ± REPAIR SIDE WIRES
2 ± STAGER CUTS
3 ± HARNESS WIRES
Fig. 19 Connector Locking Wedge Tab (Typical)
1 ± CONNECTOR
2 ± CONNECTOR LOCKING WEDGE TAB
Fig. 20 Terminal Removal
1 ± CONNECTOR
2 ± FROM SPECIAL TOOL KIT 6680
Fig. 21 Terminal Removal Using Special Tool
1 ± FROM SPECIAL TOOL KIT 6680
2 ± CONNECTOR
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SERVICE PROCEDURES (Continued)

(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys-
tems.
Fig. 22 Diode Identification
1 ± CURRENT FLOW
2 ± BAND AROUND DIODE INDICATES CURRENT FLOW
3 ± DIODE AS SHOWN IN THE DIAGRAMS
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SERVICE PROCEDURES (Continued)