DODGE NEON 1999 Service Repair Manual

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 11).
(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso-
line container. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 12). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.
(5) Replace Pressure test port cap when finished
doing pressure test.
DRAINING FUEL TANK
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle on hoist.(5) Remove quick connect cap from drain port. The
drain port is located on rear top of fuel tank. Push a
siphon hose into the drain port (Fig. 13).
(6) Drain fuel tank into holding tank or a properly
labeledGasolinesafety container.
HOSES AND CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
Fig. 11 Fuel Pressure Test PortÐTypical
Fig. 12 Releasing Fuel Pressure
Fig. 13 Drain Port Location
14 - 10 FUEL SYSTEMPL

The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 14).Do not rely upon the
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 15). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
FUEL PUMP MODULE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Drain the fuel. Refer to Draining Fuel Tank in
the Fuel Tank section of this group.
Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube
Connection
Fig. 15 Power Distribution Center (PDC)
PLFUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)

WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
(2) Disconnect fuel line from fuel pump module by
depressing quick connect retainers with thumb and
fore finger.
(3) Slide fuel pump module electrical connecter
lock to unlock.
(4) Disconnect the electrical connection from the
fuel pump module, by pushing down on connector
retainer and pulling connector off of module.
(5) Use a transmission jack to support the fuel
tank. remove bolts from fuel tank straps.
(6) Lower tank slightly.
(7) Use Special Tool 6856 to remove fuel pump
module locknut (Fig. 17).
(8) Remove fuel pump and O-ring seal from tank.
Discard old seal.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
seal in position in the tank opening.
(2) Position fuel pump in the tank. Make sure the
aligment tab on the underside of the fuel pump mod-
ule flange sits in the notch on the fuel tank.
(3)
Position the locknut over the fuel pump module.
(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 17).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE
SERVICING THE FUEL FILTER/FUEL PRESSURE REG-
ULATOR, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 18) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 19).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 16 Fuel Pump Module Removal
Fig. 17 Fuel Tank Locknut
14 - 12 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 20).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) P
ush strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the res-
ervoir body lock over the locking tangs on the strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 21).
(2) Pull off blue locking wedge (Fig. 22).
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 23).
(4) Push level sensor signal and ground terminals
out of the connector (Fig. 24).
(5) Insert a screwdriver between the fuel pump
module and the top of the level sensor housing (Fig.
25). Push level sensor down slightly.
Fig. 18 Locking Spring Tab
Fig. 19 Spring Tab In Locating Slot
Fig. 20 Inlet Strainer Removal
Fig. 21 Fuel Pump/Level Sensor Electrical
Connector
PLFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)

(6) Slide level sensor wires through opening fuel
pump module (Fig. 26).
(7) Slide level sensor out of installation channel in
module.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 25).
(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 26). Ensure tab at bottom of sensor locks in
place.(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL INJECTORS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure in this section.
(3) Disconnect fuel supply tube from rail. Refer to
Quick-Connect Fittings in the Fuel Delivery section
of this group.
(4) Disconnect electrical connectors from fuel injec-
tors (Fig. 27).
Fig. 22 Wire Terminal Locking Wedge
Fig. 23 Wire Terminal Locking Finger
Fig. 24 Removing Wires From Connector
Fig. 25 Loosening Level Sensor
Fig. 26 Level Sensor Removal/Installation
14 - 14 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 28).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 29).
INSTALLATION
(1) Apply a light coating of clean engine oil to the
upper O-ring.(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N´m63 N´m
(200630 in. lbs.).
(6) Attach electrical connectors to fuel injectors.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
FUEL TANK
REMOVAL
(1) Perform fuel system pressure release.
(2) Drain fuel tank. Refer to Draining Fuel Tank
in this section (Fig. 30).
(3) Raise vehicle on hoist.
WARNING: WRAP SHOP TOWELS AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(4) Disconnect fuel pump module electrical connec-
tor (Fig. 31).
(5) Disconnect the fuel tube from Fuel Filter/Reg-
ulator. Refer to Quick Connect Fittings in the Fuel
Delivery section of this group.
(6) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly.
(7) Disconnect fuel filler tube and filler vent tube
from filler hose at fuel tank (Fig. 32).
(8) Disconnect fuel filler vapor relief tube from tee
connecting it to the tank vapor relief tube and EVAP
canister tube.
(9) Disconnect vapor line from Evap canister tube.
(10) Remove tank mounting straps and lower tank.Fig. 27 Fuel Rail and Injectors
Fig. 28 Fuel Injector Retainer
Fig. 29 Fuel Injector O-Rings
Fig. 30 Fuel Tank
PLFUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack.
(2) Raise tank into position. Connect fuel filler
tube tank inlet nipple.
(3) Tighten fuel tank strap nuts to 22.5 N´m (200
in. lbs.) torque. Remove transmission jack. Ensure
straps are not twisted or bent.
(4) Attach fuel tubes to pump module and chassis
fuel tube. Refer to Quick Connect Fittings in the Fuel
Delivery section of this Group.
(5) Connect fuel vapor tube to tee, then to Evap
canister tube.
(6)
Attach electrical connector to fuel pump module.
(7) Lower vehicle.
(8) Fill fuel tank, install filler cap, and connect
battery cable.
CAUTION: When using the ASD Fuel System Test, the
Auto Shutdown (ASD) Relay remains energized for
either 7 minutes, until the test is stopped, or until the
ignition switch is turned to the Off position.
(9) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL FILLER NECK
REMOVAL
(1) Loosen fuel filler tube cap.
(2) Remove fuel filler neck screws (Fig. 33).
(3) Disconnect fuel fill vapor tube.
(4) Disconnect fuel filler tube from fuel tank.
Remove filler neck.
INSTALLATION
(1) Reverse for installation.
FUEL FILLER TUBE ROLLOVER VALVE
REMOVAL
The rollover valve is mounted in the fuel filler tube
(Fig. 34).
(1) To release fuel tank pressure, remove the fuel
filler tube cap.
Fig. 31 Fuel Pump Module Electrical Connector
Fig. 32 Fuel Filler Tube and Vent Tubes
Fig. 33 Fuel Filler Neck
Fig. 34 Fuel Filler Tube Rollover Valve
14 - 16 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(2) Disconnect vapor tube from rollover valve.
(3) Using a straight screwdriver, pry the valve out
of the grommet in the fuel filler tube.
INSTALLATION
(1) Apply a light coating of power steering fluid to
the grommet.
(2) Install valve in grommet.
(3) Attach vapor tube to valve.
(4) Install fuel filler tube cap.
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Working from the engine compartment, remove
the throttle control shield.
(2) Hold the throttle body throttle lever in the
wide open position. Remove the throttle cable from
the throttle body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 35) and (Fig. 36).
(4) Working from the engine compartment, remove
nuts from accelerator pedal attaching studs (Fig. 35).
Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts
to 12 N´m (105 in. lbs.) torque.(2) From inside the vehicle, hold up the pedal and
install the throttle cable and cable retainer in the
upper end of the pedal shaft.
(3) From the engine compartment, hold the throt-
tle body lever in the wide open position and install
the throttle cable. Install the throttle control shield.
THROTTLE CABLEÐMANUAL TRANSMISSION
REMOVAL
(1) Remove throttle control shield (Fig. 37).
(2) Working from the engine compartment, remove
the throttle cable from the throttle body lever (Fig.
38) and (Fig. 39).
Fig. 35 Accelerator Pedal and Throttle CableÐFront
View
Fig. 36 Accelerator Pedal and Throttle CableÐRear
View
Fig. 37 Throttle Control Shield
PLFUEL SYSTEM 14 - 17
REMOVAL AND INSTALLATION (Continued)

(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) From inside the vehicle, hold the accelerator
pedal up and remove the cable retainer and cable
from upper end of pedal shaft (Fig. 35) and (Fig. 36).
(5) Remove retainer clip from throttle cable and
grommet at the dash panel.
(6) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet.
(2) Install cable housing (throttle body end) into
the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up pedal and feed
throttle cable core wire through hole in upper end of
the pedal shaft. Install cable retainer.
(4) Install cable retainer clip.(5) From the engine compartment, rotate the
throttle lever forward to the wide open position and
install cable clasp (Fig. 39).
(6) Install throttle control shield (Fig. 37). Tighten
screw to 5.6 N´m (50 in. lbs.).
THROTTLE CABLEÐAUTOMATIC TRANSMISSION
REMOVAL
(1) Remove throttle control shield (Fig. 37).
(2) Working from the engine compartment, remove
throttle cable from throttle body cam (Fig. 40) and
(Fig. 41).
(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) From inside the vehicle, hold the throttle pedal
up and remove the cable retainer and cable from
upper end of pedal shaft (Fig. 35) and (Fig. 36).
(5) Remove retainer clip from throttle cable and
grommet at the dash panel.
Fig. 38 Throttle Cable Attachment to Throttle Body
Fig. 39 Disconnecting Throttle Cable
Fig. 40 Throttle Body Cables Attachment to Throttle
Body
Fig. 41 Disconnecting Throttle Cable
14 - 18 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(6) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet.
(2) Install cable housing (throttle body end) into
the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up pedal and feed
throttle cable core wire through hole in upper end of
the pedal shaft. Install cable retainer (Fig. 36).
(4) Install cable retainer clip.
(5) From the engine compartment, rotate the
throttle lever forward to the wide open position and
install cable clasp (Fig. 41).
(6) Install throttle control shield (Fig. 37). Tighten
to 5.6 N´m (50 in. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Accelerator Pedal to Dash Nuts...........12N´m
(105 in. lbs.)
Fuel Pump Module Locknut.....55N´m(40ft.lbs.)
Fuel Tank Strap Bolts.......22.5 N´m (200 in. lbs.)
Fuel Rail Bolts..............23N´m(195 in. lbs.)
Ignition Coil Mounting Bolts....11N´m(95in.lbs.)
Intake Manifold Bolts..........11N´m(95in.lbs.)
Throttle Control Shield........5.6 N´m (50 in. lbs.)
FUEL TANK CAPACITY
Vehicle Liters U.S. Gallons
PL 47 12.5
Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
PLFUEL SYSTEM 14 - 19
REMOVAL AND INSTALLATION (Continued)