Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Neon 1997.1999.2000.2004 Approved Dodge Neon 1997 EPL_8L
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PL LAMPS 8L - 1
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 15 LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 5 LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 11
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . 8 LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 14
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION DIAGNOSIS AND TESTING
DAYTIME RUNNING LAMP MODULE . . . . . . . . . 1 DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 1 FOG LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . 4
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1 HEADLAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
GENERAL INFORMATION excessive force or bend a component to remove it.
Each vehicle is equipped with various lamp assem- Before damaging a trim component, verify hidden
blies. A good ground is necessary for proper lighting fasteners or captured edges are not holding the com-
operation. Grounding is provided by the lamp socket ponent in place.
when it comes in contact with the metal body, or
through a separate ground wire. DAYTIME RUNNING LAMP MODULE
When changing lamp bulbs check the socket for PL vehicles built for use in Canada are equipped
corrosion. If corrosion is present, clean it with a wire with a Daytime Running Lamp (DRL) system. The
brush and coat the inside of the socket lightly with DRL system operates the headlamps at 50% illumi-
Mopar Multi-Purpose Grease or equivalent. nation with the headlamp switch OFF, park brake
released and the ignition ON. The DRL system is
SAFETY PRECAUTIONS controlled by the Daytime Running Lamp Module.
The DRL module overrides the headlamp switch
WARNING: EYE PROTECTION SHOULD BE USED when the headlamps are turned OFF. The headlamps
WHEN SERVICING GLASS COMPONENTS. PER- operate normally when the headlamps are turned
SONAL INJURY CAN RESULT. ON.
CAUTION: Do not touch the glass of halogen bulbs DIAGNOSIS AND TESTING
with fingers or other possibly oily surface, reduced
bulb life will result. DIAGNOSTIC PROCEDURES
Do not use bulbs with higher candle power than When a vehicle experiences problems with the
indicated in the Bulb Application table at the end of headlamp system, verify the condition of the battery
this group. Damage to lamp can result. connections, charging system, headlamp bulbs, wire
Do not use fuses, circuit breakers or relays hav- connectors, relay, high beam dimmer switch and
ing greater amperage value than indicated on the headlamp switch. Refer to Group 8W, Wiring Dia-
fuse panel or in the Owners Manual. grams for component locations and circuit informa-
tion.
8L - 2 LAMPS PL
DIAGNOSIS AND TESTING (Continued)
HEADLAMP DIAGNOSIS
Always begin any diagnosis by testing all of the
fuses and circuit breakers in the system. Refer to
Group 8W, Wiring Diagrams.
Conventional and halogen headlamps are inter-
changeable. It is recommended that they not be
intermixed on a given vehicle.
PL LAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)
.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM WITH 1. Loose or corroded battery 1. Clean and secure battery cable
ENGINE IDLING OR IGNITION cables. clamps and posts.
TURNED OFF. 2. Loose or worn generator drive 2. Adjust or replace generator drive
belt. belt.
3. Charging system out too low. 3. Test and repair charging system,
refer to Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer
to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations, refer to Group
8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN OUT 1. Charging system output too high. 1. Test and repair charging system,
FREQUENTLY. refer to Group 8A.
2. Loose or corroded terminals or 2. Inspect and repair all connectors
splices in circuit. and splices, refer to Group 8W.
HEADLAMPS ARE DIM WITH 1. Charging system output too low. 1. Test and repair charging system,
ENGINE RUNNING ABOVE IDLE.* refer to Group 8A.
2. Poor headlamp circuit ground. 2. Test voltage drop across
Z1-ground, refer to Group 8W.
3. High resistance in headlamp 3. Test amperage draw of headlamp
circuit. circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH RANDOMLY. 1. Poor headlamp circuit ground. 1. Repair circuit ground, refer to
Group 8W.
2. High resistance in headlamp 2. Test amperage draw of headlamp
circuit. circuit.
3. Faulty headlamp switch circuit 3. Replace headlamp switch.
breaker.
4. Loose or corroded terminals or 4. Repair connector terminals or
splices in circuit. splices, refer to Group 8W.
HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Replace fuse, refer to Group 8W.
ILLUMINATE. 2. No ground at headlamps. 2. Repair circuit ground, refer to
Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer switch. 4. Replace headlamp dimmer
switch.
5. Broken connector terminal or 5. Repair connector terminal or wire
wire splice in headlamp circuit. splices.
* Canada vehicles must have lamps ON.
8L - 4 LAMPS PL
DIAGNOSIS AND TESTING (Continued)
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM WITH 1. Loose or corroded battery 1. Clean and secure battery cable
ENGINE IDLING OR IGNITION cables. clamps and posts.
TURNED OFF. 2. Loose or worn generator drive 2. Adjust or replace generator drive
belt. belt.
3. Charging system output too low. 3. Test and repair charging system,
refer to Group 8A.
4. Battery has insufficient charge. Test battery state-of-charge, refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations, refer to Group
8W.
7. Both fog lamp bulbs defective. 7. Replace both lamp bulbs.
FOG LAMP BULBS BURN OUT 1. Charging system output too high. 1. Test and repair charging system,
FREQUENTLY. refer to Group 8A.
2. Loose or corroded terminals or 2. Inspect and repair all connectors
splices in circuit. and splices, refer to Group 8W.
FOG LAMPS ARE DIM WITH 1. Charging system output too low. 1. Test and repair charging system,
ENGINE RUNNING ABOVE IDLE. refer to Group 8A.
2. Poor fog lamp circuit ground. 2. Test voltage drop across
Z1-ground, refer to Group 8W.
3. High resistance in fog lamp 3. Test amperage draw of fog lamp
circuit. circuit.
4. Both fog lamp bulbs defective. 4. Replace both fog lamp bulbs.
FOG LAMPS FLASH RANDOMLY. 1. Poor fog lamp circuit ground. 1. Repair circuit ground, refer to
Group 8W.
2. High resistance in fog lamp 2. Test amperage draw of fog lamp
circuit. circuit.
3. Faulty fog lamp switch circuit 3. Replace fog lamp switch.
breaker.
4. Loose or corroded terminals or 4. Repair connector terminals or
splices in circuit. splices, refer to Group 8W.
FOG LAMPS DO NOT 1. Blown fuse for log lamps. 1. Replace fuse, refer to Group 8W.
ILLUMINATE. 2. No ground at fog lamps. 2. Repair circuit ground, refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or 4. Repair connector terminal or wire
wire splice in fog lamp circuit. splices.
PL LAMPS 8L - 5
HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION HEADLAMP ADJUSTMENT USING ALIGNMENT
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 5 SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES SPECIAL TOOLS
HEADLAMP ALIGNMENT PREPARATION . . . . . . 5 SPECIAL TOOLS--HEADLAMP ALIGNMENT . . . 7
ADJUSTMENTS
FOG LAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION (4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
HEADLAMP ALIGNMENT (5) Jounce front suspension three times by pushing
Headlamps can be aligned using the screen method downward on front bumper and releasing.
provided in this section. Alignment Tool C4466-A or (6) Measure the distance from the center of head-
equivalent can also be used. Refer to instructions lamp lens to the floor. Transfer measurement to the
provided with the tool for proper procedures. The alignment screen (with tape). Use this line for
preferred headlamp alignment setting is 0 for up/down adjustment reference.
the left/right adjustment and 0 for the up/down (7) Measure distance from the centerline of the
adjustment. vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
SERVICE PROCEDURES side of vehicle centerline. Use these lines for left/
right adjustment reference.
HEADLAMP ALIGNMENT PREPARATION HEADLAMP ADJUSTMENT
(1) Verify headlamp dimmer switch and high beam A properly aimed low beam headlamp will project
indicator operation. the top edge of low beam hot spot on the alignment
(2) Inspect and correct damaged or defective com- screen from 50 mm (2 in.) above to 50 mm (2 in.)
ponents that could interfere with proper headlamp below the headlamp centerline. The side- to-side left
alignment. edge of low beam hot spot should be from 50 mm (2
(3) Verify proper tire inflation. in.) left to 50mm (2 in.) right of headlamp centerline
(4) Clean headlamp lenses. (Fig. 1). The preferred headlamp alignment is 0
(5) Verify that luggage area is not heavily loaded. for the up/down adjustment and 0 for the left/
(6) Fuel tank should be FULL. Add 2.94 kg (6.5 right adjustment. The high beams on a vehicle
lbs.) of weight over the fuel tank for each estimated with aero headlamps cannot be aligned. The high
gallon of missing fuel. beam pattern should be correct when the low beams
are aligned properly.
ADJUSTMENTS To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
HEADLAMP ADJUSTMENT USING ALIGNMENT pattern.
SCREEN FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to Alignment
ALIGNMENT SCREEN PREPARATION Screen Preparation paragraph in this section. Disen-
(1) Position vehicle on a level surface perpendicu- gage the wire connectors from the back of the head-
lar to a flat wall 7.62 meters (25 ft) away from front lamp bulbs to disable the headlamps. This will allow
of headlamp lens (Fig. 1). a more accurate projection reading of the fog lamps.
(2) If necessary, tape a line on the floor 7.62 Turn on the headlamp switch and actuate the fog
meters (25 ft) away from and parallel to the wall. lamp switch. A properly aligned fog lamp will project
(3) From the floor up 1.27 meters (5 ft), tape a line a pattern on the alignment screen 100 mm (4 in.)
on the wall at the centerline of the vehicle. Sight below the fog lamp centerline and straight ahead
along the centerline of the vehicle (from rear of vehi- (Fig. 2).
cle forward) to verify accuracy of the line placement.
VEHICLE CENTER LINE (25 FT.)
HEADLAMP HEADLAMP OF
CENTER
FLOOR
OF LINE
7.62 METERS FRONTTER CEN-HEADLAMP
TO
8L - 6 LAMPS PL
SPECIAL TOOLS (Continued)
CENTER LINE FOG
7.62 METERSCENTER LINE HOT SPOT
OF LAMPS (25 FT.) FOG LAMP OF VEHICLE LAMP INS.
FLOOR TOOF FOG
FRONT CENTER LAMPFOG
4
Fig. 1 Headlamp Alignment Screen--Typical
Fig. 2 Lamp Alignment Screen
PL LAMPS 8L - 7
SPECIAL TOOLS
SPECIAL TOOLS--HEADLAMP ALIGNMENT
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