2000 DODGE NEON electrical

GROUP TAB LOCATORINIntroductionINaIntroduction0Lubrication and Maintenance2Suspension3Differential and Driveline5Brakes6Clutch7Cooling8ABattery8BStarting8CCharging System8DIgnition System8EInstrument Panel and Systems8EaInstrument Panel and Systems8FAudio System8GHorns8HVehicle Speed Control System8JTurn Signal and Flashers8KWindshield Wipers and Washers8LLamps8LaLamps8MRestraint System8NElectrically Heated Systems8OPower Distribution Systems8PPower Door Locks8QImmobilizer System8SPower Windows8TPower Mirrors8TaPower Mirrors8UChime Warning/Reminder System8WWiring Diagrams - LHD and RHD9Engine11Exhaust System13Frame and Bumpers14Fuel System19Steering21Transaxle22Tires and Wheels23Body24Heating and Air Conditioning24aHeating and Air Conditioning25Emission Control Systems

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES................3
SPECIFICATIONS
UNSCHEDULED INSPECTION................3SCHEDULE ± A...........................3
SCHEDULE ± B...........................4
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Extensive idling
²More than 50% of the driving is at sustained
high speeds during hot weather, above 90É F (32É C)
SPECIFICATIONS
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
every other interval on Schedule ± B (6,000 miles -
10 000 km).
²Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable group.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km) or at 12 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
PLLUBRICATION AND MAINTENANCE 0 - 3

JUMP STARTING, TOWING, AND HOISTING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
JUMP STARTING PROCEDURE...............7
TOWING RECOMMENDATIONS...............7
HOISTING RECOMMENDATIONS.............7SERVICE PROCEDURES
JUMP STARTING PROCEDURE...............7
TOWING RECOMMENDATIONS...............8
HOISTING RECOMMENDATIONS.............9
DESCRIPTION AND OPERATION
JUMP STARTING PROCEDURE
Describes the procedure for starting a disable vehi-
cle.
TOWING RECOMMENDATIONS
Describes the recommended towing procedures.
HOISTING RECOMMENDATIONS
Describes the location of hoisting and jacking
points so that the vehicle can be lifted by a floor jack
or hoist.
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, place
the 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-
PLLUBRICATION AND MAINTENANCE 0 - 7

PARKING BRAKE LEVER
WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARKING
BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER ADJUSTMENT MECHANISM CAN BE
LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.
REMOVAL
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the wiring harness electrical connector
from the parking brake warning lamp switch on the
parking brake lever (Fig. 95).
(8) Remove the two nuts attaching the parking
brake lever to the vehicle (Fig. 95).
(9) Remove the parking brake lever from the vehi-
cle.
Fig. 93 Pin Punch Installed
1 ± PARKING BRAKE LEVER
2 ± PIN PUNCH
3 ± OUTPUT CABLE
Fig. 94 Parking Brake Cables At Equalizer
1 ± LEVER OUTPUT CABLE
2 ± EQUALIZER
3 ± REAR PARKING BRAKE CABLES
5 - 48 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place the parking brake lever on the mounting
studs on the vehicle floor. Install and tighten the two
mounting nuts to a torque of 28 N´m (250 in. lbs.)
(Fig. 95).
(2) Connect the wiring harness electrical connector
on the parking brake warning lamp switch (Fig. 95).
(3) Install both rear park brake cables into the
equalizer on the parking brake lever output cable
(Fig. 94).
(4) Ensure that the parking brake cables are cor-
rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster.
(5) Keeping your hands clear of the automatic
adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (or locking pin if a new
mechanism has been installed) (Fig. 93), then quickly
remove it from the parking brake lever mechanism.
This will allow the park brake lever mechanism to
automatically adjust the parking brake cables.
(6) Cycle the parking brake lever once to position
the parking brake cables, then return the parking
brake lever its released position.
(7) Check the rear wheels of the vehicle. They
should rotate freely without dragging with the lever
in its released position.
(8) Fully apply the parking brake lever.
(9) Install the center console and its mounting
screws.
(10) Remove the blocks from the tires and wheels.
PARKING BRAKE CABLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
The procedure below applies to either of the two
rear parking brake cables.
REMOVAL
(1) Block the tire and wheels so the vehicle does
not move once the vehicle parking brake lever is
released.
(2) Fully apply the parking brake lever, then shift
the transmission into neutral.
(3) Remove the screws attaching the center con-
sole, then remove the center console.
(4) Lower the parking brake lever handle to the
released position.
(5) Grasp the parking brake lever output cable by
hand and pull upward. Continue pulling on the cable
until a pin punch can be inserted through the hole in
the lever mechanism sector gear and the hole in the
right side of its mounting bracket (Fig. 93). This will
lock the parking brake automatic adjustment mecha-
nism in place and take tension off the parking brake
cables.
(6) Remove both rear parking brake cables from
the parking brake cable equalizer (Fig. 94).
(7) Remove the rear seat cushion from the vehicle.
(8) Fold the rear carpeting forward to expose the
parking brake cables at the end of the rear floor.
(9) Install the box end of a 1/2 inch wrench over
the parking brake cable retainer (Fig. 96). Push the
wrench onto the retainer until the retainer fingers
are collapsed. From under the carpeting, grasp the
parking brake cable housing and pull cable straight
out of the bracket attached to the floor.
(10) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(11) Remove the rear tire and wheel assembly
from the vehicle.
(12) On vehicles equipped with rear drum brakes,
remove the brake drum. Refer to BRAKE DRUM in
this section of this service manual group.
(13) On vehicles equipped with rear disc brakes:
²Remove the disc brake caliper guide pin bolts,
then the caliper from disc brake adapter (Fig. 97).
²Hang the caliper out of the way using a wire
hanger or cord.
²Remove the brake rotor from the rear hub and
bearing.
(14) Remove the dust cap from the rear hub and
bearing.
Fig. 95 Parking Brake Lever
1 ± MOUNTING NUTS
2 ± PARKING BRAKE LEVER
3 ± PARKING BRAKE WARNING LAMP SWITCH CONNECTOR
PLBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION......65
ANTILOCK BRAKE SYSTEM COMPONENTS....66
ELECTRONIC BRAKE DISTRIBUTION.........69
TRACTION CONTROL SYSTEM..............70
HYDRAULIC CIRCUITS AND VALVE
OPERATION...........................71
DIAGNOSIS AND TESTING
SERVICE WARNINGS AND CAUTIONS........74
ABS GENERAL DIAGNOSTICS INFORMATION . . 74
ABS WIRING DIAGRAM INFORMATION........74
ABS VEHICLE TEST DRIVE.................74
ABS ELECTRONIC DIAGNOSIS..............75
TONE WHEEL...........................76
BRAKE FLUID CONTAMINATION.............76
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING............77ANTILOCK BRAKE SYSTEM BLEEDING.......77
MASTER CYLINDER BLEEDING.............77
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........78
MASTER CYLINDER......................78
INTEGRATED CONTROL UNIT...............79
WHEEL SPEED SENSOR (FRONT)...........81
WHEEL SPEED SENSOR (REAR)............83
DISASSEMBLY AND ASSEMBLY
INTEGRATED CONTROL UNIT...............84
SPECIFICATIONS
TONE WHEEL RUNOUT....................85
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE...........................85
BRAKE FASTENER TORQUE
SPECIFICATIONS.......................85
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION
This section covers the physical and operational
descriptions, and the on-car service procedures for
the Mark 20e Antilock Brake System (ABS) with
traction control. It is the only antilock brake system
available on this vehicle.
The purpose of the antilock brake system is to pre-
vent wheel lockup under braking conditions on virtu-
ally any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
The traction control system reduces wheel slip and
maintains traction at the driving speeds below 56
kph (35 mph) when road conditions call for traction
assistance. Refer to TRACTION CONTROL SYSTEM
in this section for more information.
Vehicles equipped with ABS use electronic brake
distribution (EBD) to balance front-to-rear braking
when the brakes are applied in the partial braking
range. Refer to ELECTRONIC BRAKE DISTRIBU-
TION in this section for more information.
There are a few performance characteristics of the
Mark 20e Antilock Brake System that may at first
seem abnormal, but in fact are normal. These char-
acteristics are described below.
NORMAL BRAKING
Under normal braking conditions, the ABS func-
tions the same as a standard base brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS BRAKING
ABS operation is available at all vehicle speeds
above 3±5 mph. If a wheel locking tendency is
detected during a brake application, the brake sys-
tem enters the ABS mode. During ABS braking,
hydraulic pressure in the four wheel circuits is mod-
ulated to prevent any wheel from locking. Each
wheel circuit is designed with a set of electric sole-
noids to allow modulation, although for vehicle sta-
bility, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into four control channels.
During antilock operation of the vehicle's brake sys-
tem, the wheels are controlled independently and are
on separate control channels.
The system can build, hold and release pressure at
each wheel, depending on signals generated by the
wheel speed sensors (WSS) at each wheel and
received at the controller antilock brake (CAB).
PLBRAKES 5 - 65

The ABS with traction control ICU consists of the
following components: the CAB, eight (build/decay)
solenoid valves (four inlet valves and four outlet
valves), two hydraulic shuttle valves, two traction
control valves, valve block, fluid accumulators, a
pump, and an electric pump/motor.
The replaceable components of the ICU are the
HCU and the CAB. No attempt should be made to
service any components found inside of the HCU or
CAB.
CONTROLLER ANTILOCK BRAKE (CAB)
The controller antilock brake (CAB) is a micropro-
cessor-based device which monitors the ABS system
during normal braking and controls it when the vehi-
cle is in an ABS stop. The CAB is mounted to the
bottom of the HCU (Fig. 2). The CAB uses a 25-way
electrical connector on the vehicle wiring harness.
The power source for the CAB is through the ignition
switch in the RUN or ON position. The CAB is on
the PCI bus.
The primary functions of the (CAB) are to:
(1) monitor the antilock brake system for proper
operation.
(2) detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
(3) control fluid modulation to the wheel brakes
while the system is in an ABS mode or the traction
control system is activated.
(4) store diagnostic information.
(5) provide communication to the DRB scan tool
while in diagnostic mode.
The CAB constantly monitors the antilock brake
system for proper operation. If the CAB detects a
fault, it will send a message to the mechanical instu-
ment cluster (MIC) instructing it to turn on the
amber ABS warning lamp and disable the antilock
braking system. The normal base braking system will
remain operational.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The CAB command coils then open and close the
valves in the HCU that modulate brake fluid pres-
sure in some or all of the hydraulic circuits. The CAB
continues to control pressure in individual hydraulic
circuits until a locking tendency is no longer present.
The CAB contains a self-diagnostic program that
monitors the antilock brake system for system faults.
When a fault is detected, the amber ABS warning
lamp is turned on and the fault diagnostic trouble
code (DTC) is then stored in a diagnostic program
memory. These DTC's will remain in the CAB mem-
ory even after the ignition has been turned off. The
DTC's can be read and cleared from the CAB mem-
ory by a technician using the DRB scan tool. If not
cleared with a DRB scan tool, the fault occurrence
and DTC will be automatically cleared from the CAB
memory after the identical fault has not been seen
during the next 3,500 miles of vehicle operation.
Fig. 1 Master Cylinder And ICU
1 ± PRIMARY BRAKE TUBE
2 ± MASTER CYLINDER
3 ± SECONDARY BRAKE TUBE
4 ± ABS ICU
Fig. 2 Integrated Control Unit (ICU)
1 ± HCU
2 ± PUMP/MOTOR
3 ± CAB
PLBRAKES 5 - 67
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
SERVICE WARNINGS AND CAUTIONS
The ABS uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.
CAUTION: In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so for a diagnostic proce-
dure.
CAUTION: These circuits should only be tested
using a high impedance multi-meter or the DRB
scan tool as described in this section. Power
should never be removed or applied to any control
module with the ignition in the ON position. Before
removing or connecting battery cables, fuses, or
connectors, always turn the ignition to the OFF
position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, etc.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
ABS GENERAL DIAGNOSTICS INFORMATION
This section contains information necessary to
diagnose the antilock brake system. Specifically, this
section should be used to help diagnose conditions
which result in any of the following:
(1) amber ABS warning lamp turned on.
(2) brakes lock-up on hard application.
Diagnosis of base brake conditions that are obvi-
ously mechanical in nature should be directed to
BASE BRAKE SYSTEM at the beginning of this
group.
Many ABS conditions judged to be a problem by
the driver may be normal operating conditions. See
ABS OPERATION in the DESCRIPTION AND
OPERATION section of this group to become famil-
iarized with the normal characteristics of this
antilock brake system.
ABS WIRING DIAGRAM INFORMATION
During the diagnosis and testing of the antilock
brake system it may become necessary to reference
the wiring diagrams covering the antilock brake sys-
tem and its components. For wiring diagrams refer to
GROUP 8W of this service manual. It will provide
you with the wiring diagrams and the circuit descrip-
tion and operation information covering the antilock
brake system.
ABS VEHICLE TEST DRIVE
Most ABS complaints will require a test drive to
properly duplicate and diagnose the condition.
WARNING: CONDITIONS THAT RESULT IN TURN-
ING ON THE RED BRAKE WARNING LAMP MAY
INDICATE REDUCED BRAKING ABILITY.
Before test driving a brake complaint vehicle, note
whether the red BRAKE warning lamp, amber ABS
warning lamp, or both are turned on. If it is the red
BRAKE warning lamp, there is a brake hydraulic
problem that must be corrected before driving the
vehicle. Refer to the BASE BRAKE SYSTEM for
diagnosis of the red BRAKE warning lamp. If the red
brake warning lamp is illuminated, there is also a
possibility that there is an ABS problem and the
amber ABS warning lamp is not able to illuminate,
so the MIC turns on the red Brake warning lamp by
default.
If the amber ABS warning lamp is on, test drive
the vehicle as described below. While the amber ABS
warning lamp is on, the ABS is not functional. The
ability to stop the car using the base brake system
should not be affected.
If a functional problem of the ABS is determined
while test driving the vehicle, refer to the Chassis
Diagnostic Procedures manual.
(1) Turn the key to the OFF position and then
back to the ON position. Note whether the amber
ABS warning lamp continues to stay on. If it does,
refer to the diagnostic manual.
(2) If the amber ABS warning lamp goes out, shift
into gear and drive the car to a speed of 20 kph (12
mph) to complete the ABS start-up and drive-off
cycles (see ABS ELECTRONIC DIAGNOSIS). If at
this time the amber ABS warning lamp comes on,
refer to the diagnostic manual.
(3) If the amber ABS warning lamp remains out,
drive the vehicle a short distance. Accelerate the
vehicle to a speed of at least 40 mph. Bring the vehi-
cle to a complete stop, braking hard enough to cause
the ABS to cycle. Again accelerate the vehicle past 25
mph. Refer to the diagnostic manual for further test-
ing of the antilock brake system.
5 - 74 BRAKESPL