check engine DODGE NEON 1999 Service User Guide

REMOVAL
(1) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(2) Mark clutch cover and flywheel, to maintain
their same relative positions when installing clutch
assembly.
(3) Insert Clutch Disc Aligning Tool 6724 through
the clutch disc hub to prevent the clutch disc from
falling and damaging the facings (Fig. 4).
(4) Loosen clutch cover attaching bolts, one or two
turns at a time, in a crisscross pattern. This will
release spring pressure evenly and avoid cover dam-
age.
CAUTION: Do not touch the clutch disc facing with
oily or dirty hands. Oil or dirt transferred from your
hands onto the clutch disc facing may cause clutch
chatter.
(5) Remove the clutch pressure plate and cover
assembly and disc from flywheel. Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
(2) The friction faces of the flywheel and pressure
plate should not have excessive discoloration, burned
areas, cracks, deep grooves, or ridges. Replace parts
as required.
(3) Clean the flywheel face with medium sandpa-
per (80-180 grade), then wipe the surface with min-
eral spirits. If the surface is severely scored, heat
checked, cracked or warped, replace the flywheel.CAUTION: Do not flat-machine the flywheel face.
The surface profile is tapered.
(4) The heavy side of the flywheel is indicated by a
daub of white paint near the outside diameter. To
minimizethe effects of flywheel unbalance, perform
the following installation procedure:
²Loose assemble the flywheel to the crankshaft.
Use new flywheel attaching bolts which have sealant
on the threads. If new bolts are not available, apply
Loctite sealant to the threads of the original bolts.
This sealant is required to prevent engine oil leak-
age.
²Rotate the flywheel and crankshaft until the
daub of white paint (heavy side) is at the 12 o'clock
position.
²Torque flywheel attaching bolts to 95 N´m (70 ft.
lbs.). Use a crisscross pattern when tightening bolts.
(5) The disc assembly should be handled without
touching the facings. Replace disc if the facings show
evidence of grease or oil soakage, or wear to within
less than .20 mm (.008 inch) of the rivet heads. The
splines on the disc hub and transaxle input shaft
should be a snug fit without signs of excessive wear.
Metallic portions of disc assembly should be dry,
clean, and not discolored from excessive heat. Each of
the arched springs between the facings should not be
broken and all rivets should be tight.
(6) Wipe the friction surface of the pressure plate
with mineral spirits.
(7) Using a straight edge, check pressure plate for
flatness. The pressure plate friction area should be
FLAT TO SLIGHTLY CONCAVE, with the inner
diameter 0.000 mm to 0.1 mm (0.000 in. to 0.0039
in.) below the outer diameter. It should also be free
from discoloration, burned areas, cracks, grooves, or
ridges.
(8) Using a surface plate, test cover for flatness.
All sections around attaching bolt holes should be in
contact with surface plate within .015 inch.
(9) The cover should be a snug fit on flywheel dow-
els. If the clutch assembly does not meet these
requirements, it should be replaced.
INSTALLATION
(1) Mount clutch assembly on flywheel with disc
centered with tool 6724, being careful to properly
align dowels and the alignment marks made before
removal. The flywheel side of the clutch disc is
marked for proper installation. If new clutch or fly-
wheel is installed, align orange cover balance spot as
close as possible to orange flywheel balance spot.
Apply pressure to the alignment tool. Center the tip
of the tool into the crankshaft and the sliding cone
into the clutch fingers. Tighten the clutch attaching
bolts sufficiently to hold the disc in position (Fig. 5).
Fig. 4 Clutch Disc Aligning Tool
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(2) To avoid distortion of the clutch cover, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 28 N´m (250 in. lbs.) following a crisscross
pattern sequence. Remove clutch disc alignment tool.
(3) Install transaxle. See Group 21, Manual Tran-
saxle for procedures.
BELVIDERE BUILT VEHICLES
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
(3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
(5) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(6) The transaxle and modular clutch come out as
an assembly.
(7) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 6). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
(3) To avoid distortion of the drive plate, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 75 N´m (55 ft. lbs.) following a crisscross pat-
tern sequence.
(4) Install clutch inspection cover.
(5) Install transaxle lower support brackets.
(6) Install starter assembly.
RELEASE BEARING AND FORK
Remove the transaxle from the vehicle. See Group
21, Transaxle for removal and installation proce-
dures.
REMOVAL
(1) Move the lever and bearing assembly to a ver-
tical in-line position. Grasp the release lever with
two hands in the pivot stud socket area. Pull with
even pressure and the lever will pop off the pivot-
±stud. Do not use a screwdriver or pry bar to pop off
the lever. This may damage the spring clip on the
lever.
(2) As a unit, remove the fork from the bearing
thrust plate. Be careful not to damage retention tabs
on bearing.
(3) Examine the condition of the bearing.It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(4) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(5) Check the condition of the pivot stud spring
clips on back side of clutch fork. If the clips are bro-
ken or distorted, replace the clutch fork.
Fig. 6 Clutch ComponentsFig. 5 Clutch Installation
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

SERVICE DIAGNOSISÐCLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft sealCorrect leak and replace w/modular
clutch assembly
Too much grease applied to splines
of disc and input shaftApply lighter coating of grease to
splines
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline componentFurther diagnosis required. Check
engine/transmission mounts,
suspension attaching parts and other
driveline components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT OF
CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly)Replace w/modular clutch assembly
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of
flywheel, disc, or cover. Check clutch
housing to engine dowels and dowel
holes for damage. Correct as
necessary.
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

(8) Grasp clutch master cylinder and turn 1/4 turn
counterclockwise (Fig. 5).
(9) Remove cylinder from dash panel.
INSTALLATION
NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
installation.
(1) Position clutch master cylinder to dash panel
approximately 45É counterclockwise. (Fig. 6).
(2) Position master cylinder push rod so that
retention fingers are facing towards the right side of
the vehicle.
(3) Insert push rod through dash panel hole and
slide push rod eye between the clutch pedal and loca-
tor bracket.
(4) Rotate cylinder 1/4 turn clockwise.
(5) Slide remote reservoir into bracket at dash
panel until locked in.(6) From underneath dash panel, ensure clutch
master cylinder push rod is located between the
pedal and locator bracket. Snap clutch pedal pin into
pushrod and slide cotter pin into bushing.
(7) Route hydraulic lines to retaining clips at
frame rail.
(8) Raise vehicle.
(9) Connect upper clutch hydraulic line from mas-
ter cylinder (quick±connect) to lower clutch hydraulic
line near damper.
(10) Check the operation of the hydraulic clutch
release system.
(11) Actuate clutch pedal rapidly 20±30 times.
Check for leaks
HYDRAULIC SLAVE CYLINDER Ð RIGHT HAND
DRIVE (RHD)
REMOVAL
(1) Raise vehicle on hoist.
(2) Separate hydraulic line at quick-disconnect
using Special Tool 6638. (Fig. 7).
(3) Remove nuts retaining hydraulic damper to
transaxle (Fig. 8).
(4) Remove engine mount bracket.
(5) Disconnect ground wire from starter.
(6) Remove two bolts retaining hydraulic slave cyl-
inder to transaxle (Fig. 8).
(7) Remove slave cylinder from transmission.
INSTALLATION
CAUTION: When reinstalling starter wiring, make
certain wiring does not contact hydraulic tubing.
(1) To install, reverse above procedure.
(2) Actuate clutch pedal 20±30 times. Check for
leaks.
Fig. 5 Hydraulic Clutch Master Cylinder
Fig. 6 Master Cylinder at Dash PanelFig. 7 Hydraulic Line
PLCLUTCH 6 - 7
REMOVAL AND INSTALLATION (Continued)

CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 9).
REMOVAL
(1) Disconnect electrical harness to switch connec-
tor.
(2) Depress wing tabs on switch and push switch
out of mounting bracket. Then slide wires through
slot in bracket.
INSTALLATION
(1) Slide switch wires through slot in switch
bracket.
(2) Line up switch tab with slot in switch bracket
and push switch into position. Do not pull on theswitch wires to seat switch into bracket, switch dam-
age may occur.
(3) Attach switch wiring harness to vehicle wiring
harness.
(4) After installation, the switch must be checked
for proper operation. Refer to Diagnosis and Testing
section for proper testing procedures.
CLUTCH ASSEMBLY Ð RIGHT HAND DRIVE (RHD)
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
(3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
(5) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(6) The transaxle and modular clutch come out as
an assembly.
(7) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 10). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.
NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
Fig. 8 Damper and Slave Cylinder
Fig. 9 Clutch Pedal Position Switch and
ComponentsFig. 10 Clutch Components
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

COOLING
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS................ 2
AUTOMATIC TRANSMISSION OIL COOLER.... 3
COOLANT RECOVERY SYSTEM (CRS)....... 2
COOLANT.............................. 3
COOLING SYSTEM PRESSURE CAP......... 3
COOLING SYSTEM....................... 1
ENGINE BLOCK HEATER.................. 3
ENGINE THERMOSTAT.................... 3
RADIATOR............................. 3
WATER PUMP.......................... 3
DESCRIPTION AND OPERATION
COOLANT PERFORMANCE................. 4
COOLING SYSTEM PRESSURE CAP......... 5
ENGINE BLOCK HEATER.................. 5
ENGINE THERMOSTAT.................... 4
RADIATOR HOSES AND CLAMPS........... 5
WATER PUMP.......................... 6
DIAGNOSIS AND TESTING
ACCESSORY DRIVEBELT DIAGNOSIS....... 13
COOLING SYSTEM DIAGNOSIS............. 7
COOLING SYSTEM FLOW CHECK.......... 14
DEAERATION.......................... 15
ELECTRIC FAN MOTOR TEST.............. 14
ENGINE THERMOSTAT TESTING........... 13
LOW COOLANT LEVEL AERATION.......... 15
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK.............. 15
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP...................... 15
RADIATOR FAN CONTROL................ 14
TEMPERATURE GAUGE INDICATION........ 16
TESTING COOLING SYSTEM FOR LEAKS.... 14WATER PUMP DIAGNOSIS............... 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE........ 16
COOLANT LEVELÐSERVICING............ 16
COOLANTÐADDING ADDITIONAL......... 16
COOLING SYSTEMÐDRAINING............ 16
COOLING SYSTEMÐREFILLING........... 17
REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELTS............... 21
ENGINE BLOCK HEATER................. 21
ENGINE THERMOSTAT................... 18
RADIATOR DRAINCOCK.................. 20
RADIATOR FANS AND MOTOR............ 20
RADIATOR............................ 19
WATER PUMP INLET TUBE............... 18
WATER PUMP......................... 17
CLEANING AND INSPECTION
ACCESSORY DRIVE BELT INSPECTION...... 22
CHEMICAL CLEANING................... 23
CLEANING COOLING SYSTEM............. 22
COOLING SYSTEM CAP.................. 22
RADIATOR FLUSHING................... 23
REVERSE FLUSHING.................... 23
WATER PUMP......................... 21
ADJUSTMENTS
BELT TENSION GAUGE METHOD........... 24
PROPER BELT TENSION................. 23
SPECIFICATIONS
COOLING SYSTEM CAPACITY............. 24
TORQUE.............................. 24
SPECIAL TOOLS
COOLING............................. 24
GENERAL INFORMATION
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, and a water pump to
circulate the coolant. The engine cooling module may
consist of a radiator, electric fan motor, fan, shroud,
coolant reserve system, transmission oil cooler, hoses,
clamps, air condition condenser and transmission oil lines.
²When the Engine is cold: The thermostat is
closed; the cooling system has no flow through the
radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open;
the cooling system has flow through radiator, engine,
heater system and bypass.
Coolant flow circuit for the 2.0L engine is shown in
(Fig. 1).
PLCOOLING 7 - 1

During any reassembly procedures all pipe fittings
in water jacket, and waterbox require cleaning and
application of thread sealant for entire length of
threads.
ACCESSORY DRIVE BELTS
If the engine is equipped with power steering or air
conditioning, it will have 2 drive belts. One belt
drives the generator, the other drives the Power
Steering and Air Conditioning. (Fig. 2)
COOLANT RECOVERY SYSTEM (CRS)
This system works in conjunction with the radiator
pressure cap to utilize thermal expansion and con-
traction of the coolant to keep the coolant free of
trapped air. The system provides space for expansionand contraction, and a convenient safe method for
checking and adjusting the coolant level at atmo-
spheric pressure without removing the pressure cap.
It also provides some reserve coolant to compensate
for minor leaks and evaporation or boiling losses. All
vehicles are equipped with this system (Fig. 3).
See Coolant Level Check, Service Procedures.
Deaeration and Pressure Cap sections for operation
and service.
Fig. 1 Cooling System Operation
Fig. 2 Drive Belts
Fig. 3 Coolant Recovery System
7 - 2 COOLINGPL
GENERAL INFORMATION (Continued)

DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
TEMPERATURE GAUGE READS
LOW1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open engine thermostat?1. Refer to On Board Diagnostic in
Group 25. Replace thermostat if
necessary. If a (DTC) has not been
set, the problem may be with the
temperature gauge.
2. Is the temperature gauge (if
equipped) connected to the
temperature gauge coolant sensor
on the engine?2. Check the connector at the
engine coolant sensor. Refer to
Group 8E. Repair as necessary.
3. Is the temperature gauge (if
equipped) operating OK?3. Check Gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low during cold
ambient temperature, accompanied
by poor heater performance.4. Check coolant level in the coolant
overflow/reserve tank and the
radiator. Inspect the system for
leaks. Repair as necessary. Refer to
WARNINGS outlined in this section
before removing pressure cap.
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM.1. Trailer being towed, a steep hill
being climbed, vehicle being
operated in slow moving traffic, or
engine idling during high ambient
(outside) temperatures with air
conditioning on. High altitudes
Could aggravate these conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and drive the vehicle
without any of the previous
conditions. Observe the temperature
gauge the gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause of the
overheating and repair. Refer to
POSSIBLE CAUSES in this section.
2. Is temperature gauge (if
equipped) reading correctly?2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Is temperature warning lamp (if
equipped) illuminating
unnecessarily?3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in overflow/reserve
tank and radiator?4. Check for coolant leaks and
repair as necessary. Refer to
checking cooling system for leaks in
this group.
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.5. Tighten cap.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator cap
Inspection. Replace cap if
necessary.
6. (b) Check condition of filler neck.
If neck is bent or damaged, replace
neck.
PLCOOLING 7 - 7

COOLING SYSTEM DIAGNOSIS CONT.
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM.7. Coolant level low in radiator but
not in coolant overflow/reserve
tank. This means the radiator is not
drawing coolant from the coolant
overflow/reserve tank as the engine
cools.
As the engine cools, a vacuum is
formed inside the cooling system. If
the radiator cap seals are defective,
or the cooling system has a leak, a
vacuum can not be formed.7. (a) Check condition of radiator
cap and cap seals. Replace cap if
necessary.
(b) Check condition of filler neck. If
neck is damaged, replace filler
neck.
(c) Check condition of hoses from
filler neck to coolant tank. It should
be tight at both ends without any
kinks or tears. Replace hose if
necessary.
(d) Check coolant overflow/reserve
tank and tank hoses for blockage.
Repair as necessary.
8. Freeze point of coolant not
correct. Mixture may be to rich.8. Check coolant. Refer to coolant
section in this group. Adjust glycol
to water ratio as required.
9. Coolant not flowing through
system.9. Check for coolant flow at filler
neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through filler neck. If flow is not
observed determine reason for lack
of flow and repair as necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.10. Clean insects or debris.
11. Radiator core is plugged or
corroded.11. Replace or re-core radiator.
12. Fuel or ignition system
problems.12. Refer to Fuel and Ignition
System group for diagnosis. Also
refer to the appropriate Powertrain
Diagnosis Procedures manual for
operation of the DRB scan tool.
13. Dragging brakes. 13. Inspect brake system and repair
as necessary. Refer to Group 5,
Brakes for diagnosis.
14. Bug screen is being used
causing reduced air flow.14. Remove bug screen.
15. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.15. Check thermostat operation and
replace as necessary. Refer to
thermostats in this group.
16. Electric cooling fan not
operating properly.16. Check electric fan operation and
repair as necessary.
17. Cylinder head gasket leaking. 17. Check cylinder head gasket for
leaks. Refer to testing cooling
system for leaks. For repairs, refer
to group 9, Engines.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.
7 - 8 COOLINGPL
DIAGNOSIS AND TESTING (Continued)

COOLING SYSTEM DIAGNOSIS CONT.
CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)1. Radiator and/or air conditioning
condenser is restricted, obstructed
or dirty.1. Remove restriction and/or clean
as necessary.
2. Electric radiator fan not operating
when a/c is on.2. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
repair as necessary.
3. Engine is overheating ( heat may
be transferred from radiator to A/C
condenser. High underhood
temperature due to engine
overheating may also transfer heat
to A/C components).3. Correct overheating condition.
Refer to Group 7, Cooling.
INADEQUATE HEATER
PERFORMANCE.1. Has a diagnostic trouble code
(DTC) been set?1. Refer to On-Board Diagnostic in
Group 25, and replace thermostat if
necessary.
2. Coolant level low. 2. Refer to testing cooling system
for leaks in this section. Repair as
necessary.
3. Obstructions in heater hose
fittings at engine.3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping
coolant to heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch. The accessory drive belt
may be slipping causing poor water
pump operation.5. Refer to water pump in this
group. Repair as necessary. If
slipping belt is detected, refer to
accessory drive belts in this group.
Repair as necessary.
HEAT ODOR 6. Various heat shields are used at
certain drive line components. One
or more of these shields may be
missing.6. Locate missing shields and
replace or repair as necessary.
PLCOOLING 7 - 11
DIAGNOSIS AND TESTING (Continued)