lock DODGE NEON 1999 Service Repair Manual

FRAME AND BUMPERS
CONTENTS
page page
BUMPERS............................... 1FRAMES................................ 3
BUMPERS
INDEX
page page
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA.................. 1
FRONT BUMPER REINFORCEMENT.......... 1REAR BUMPER FASCIA................... 1
REAR BUMPER REINFORCEMENT........... 2
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
(1) Remove nuts holding front bumper fascia
bracket to bottom of fender forward of front wheels.
(2) Remove screws holding front fascia to inner
wheelhouse.
(3) Remove bolts holding fascia to bumper rein-
forcement forward of radiator (Fig. 1).
(4) Remove bolts holding fascia to bottom of
bumper reinforcement.
(5) Separate fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install bolts holding fascia to bottom of bumper
reinforcement.
(3) Install bolts holding fascia to bumper reinforce-
ment forward of radiator (Fig. 1).
(4) Install screws holding front fascia to inner
wheelhouse.
(5) Install radiator grille, refer to Group 23, Body
for proper procedures.
FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front fascia.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Remove nuts holding reinforcement to radiator
closure panel (Fig. 2).
(4) Separate bumper reinforcement from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR BUMPER FASCIA
REMOVAL
(1) Release trunk lock and open trunk lid.
(2) Remove bolts holding fascia to tail closure
panel.
(3) Remove push±in fasteners holding fascia to
bottom of rear bumper reinforcement (Fig. 3).
Fig. 1 Front Bumper Fascia
PLFRAME AND BUMPERS 13 - 1

FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids
(Fig. 4). The injector contains a pintle that closes off
an orifice at the nozzle end. When electric current is
supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel
to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a
hollow cone. The spraying action atomizes the fuel,
adding it to the air entering the combustion chamber.
The injectors are positioned in the intake manifold.
Fuel injectors are not interchangeable between
engines.
The injectors are positioned in the intake manifold
with the nozzle ends directly above the intake valve
port (Fig. 5).
PRESSURE-VACUUM FILLER CAP
The loss of any fuel or vapor out of the filler neck
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum
release for all gas caps is between 0.97 and 2.0 kPa
(0.14 and 0.29 psi). The cap must be replaced by a
similar unit if replacement is necessary.WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with
plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 6).
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 6). When the fuel tube
enters the fitting, the retainer locks the shoulder of
the nipple in place and the O-rings seal the tube.
ROLLOVER VALVES
All PL vehicles have two rollover valves. One in
the fuel filler tube and the other on the top of the
fuel tank. The valves prevent fuel flow through the
fuel tank vent valve hoses should the vehicle rollover.
Fig. 3 Fuel RailÐTypical
Fig. 4 Fuel Injector
Fig. 5 Fuel Injector LocationÐTypical
PLFUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)

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)

(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)

CRANKSHAFT POSITION SENSORÐPCM INPUT
The PCM determines what cylinder to fire from the
crankshaft position sensor input and the camshaft
position sensor input. The second crankshaft counter-
weight has two sets of four timing reference notches
including a 60 degree signature notch (Fig. 7). From
the crankshaft position sensor input the PCM deter-
mines engine speed and crankshaft angle (position).
The notches generate pulses from high to low in
the crankshaft position sensor output voltage. When
a metal portion of the counterweight aligns with the
crankshaft position sensor, the sensor output voltage
goes low (less than 0.5 volts). When a notch aligns
with the sensor, voltage goes high (5.0 volts). As a
group of notches pass under the sensor, the outputvoltage switches from low (metal) to high (notch)
then back to low.
If available, an oscilloscope can display the square
wave patterns of each voltage pulses. From the width
of the output voltage pulses, the PCM calculates
engine speed. The width of the pulses represent the
amount of time the output voltage stays high before
switching back to low. The period of time the sensor
output voltage stays high before switching back to
low is referred to as pulse width. The faster the
engine is operating, the smaller the pulse width on
the oscilloscope.
By counting the pulses and referencing the pulse
from the 60 degree signature notch, the PCM calcu-
lates crankshaft angle (position). In each group of
timing reference notches, the first notch represents
69 degrees before top dead center (BTDC). The sec-
ond notch represents 49 degrees BTDC. The third
notch represents 29 degrees. The last notch in each
set represents 9 degrees before top dead center
(TDC).
The timing reference notches are machined at 20É
increments. From the voltage pulse width the PCM
tells the difference between the timing reference
notches and the 60 degree signature notch. The 60
degree signature notch produces a longer pulse width
than the smaller timing reference notches. If the
camshaft position sensor input switches from high to
low when the 60 degree signature notch passes under
the crankshaft position sensor, the PCM knows cylin-
der number one is the next cylinder at TDC.
The crankshaft position sensor mounts to the
engine block behind the alternator, just above the oil
filter (Fig. 8).
ENGINE COOLANT TEMPERATURE SENSORÐPCM
INPUT
The combination coolant temperature sensor has
two elements. One element supplies coolant temper-
ature signal to the PCM. The other element supplies
coolant temperature signal to the instrument panel
gauge cluster. The PCM determines engine coolant
temperature from the coolant temperature sensor.
As coolant temperature varies the coolant temper-
ature sensors resistance changes resulting in a differ-
ent input voltage to the PCM and the instrument
panel gauge cluster.
When the engine is cold, the PCM will provide
slightly richer air- fuel mixtures and higher idle
speeds until normal operating temperatures are
reached.
SOHC
The coolant sensor threads into the rear of the cyl-
inder head, next to the camshaft position sensor (Fig.
9). New sensors have sealant applied to the threads.
Fig. 5 Target MagnetÐTypical
Fig. 6 Target Magnet Polarity
14 - 26 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

As Intake Air temperature varies the Intake Air
Temperature sensors resistance changes resulting in
a different input voltage to the PCM.
The IAT sensor and Manifold Absolute Pressure
(MAP) switch are a combined into a single sensor
that attachs to the intake manifold (Fig. 13) or (Fig.
14).
KNOCK SENSORÐPCM INPUT
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 15). When the
knock sensor detects a knock in one of the cylinders,
it sends an input signal to the PCM. In response, the
PCM retards ignition timing for all cylinders by a
scheduled amount.
Knock sensors contain a piezoelectric material
which sends an input voltage (signal) to the PCM. As
the intensity of the engine knock vibration increases,
the knock sensor output voltage also increases.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT
The PCM supplies 5 volts direct current to the
MAP sensor. The MAP sensor converts intake mani-
fold pressure into voltage. The PCM monitors the
MAP sensor output voltage. As vacuum increases,
MAP sensor voltage decreases proportionately. Also,
as vacuum decreases, MAP sensor voltage increases
proportionately.
At key on, before the engine is started, the PCM
determines atmospheric air pressure from the MAP
sensor voltage. While the engine operates, the PCM
determines intake manifold pressure from the MAP
sensor voltage. Based on MAP sensor voltage and
inputs from other sensors, the PCM adjusts spark
advance and the air/fuel mixture.
The MAP/Intake Air Temperature sensor mounts to
the intake manifold (Fig. 13) and (Fig. 14).
Fig. 12 Downstream Heated Oxygen Sensor
Fig. 13 / MAP/Intake Air Temperature SensorÐSOHC
Fig. 14 MAP/Intake Air Temperature SensorÐDOHC
Fig. 15 Knock Sensor
PLFUEL SYSTEM 14 - 29
DESCRIPTION AND OPERATION (Continued)

(9) Rotate throttle lever forward to the wide open
position and slide kickdown cable connector onto nail
head.
(10) Install throttle cable cover. Tighten bolt to 5.6
N´m (50 ins. lbs.).
THROTTLE POSITION SENSOR (TPS)
The throttle position sensor attaches to the side of
the throttle body (Fig. 93).
REMOVAL
(1) Disconnect EVAP purge hose from throttle
body.
(2) Disconnect electrical connector from idle air
control motor and throttle position sensor.
(3) Remove throttle body. Refer to Throttle Body in
this section.
(4) Remove throttle position sensor mounting
screws.
(5) Remove throttle position sensor.
INSTALLATION
(1) The throttle shaft end of the throttle body
slides into a socket in the TPS (Fig. 94). The socket
has two tabs inside it. The throttle shaft rests
against the tabs. When indexed correctly, the TPS
can rotate clockwise a few degrees to line up the
mounting screw holes with the screw holes in the
throttle body. The TPS has slight tension when
rotated into position. If it is difficult to rotate the
TPS into position, install the sensor with the throttle
shaft on the other side of the tabs in the socket.
Tighten mounting screws to 2 N´m (17 in. lbs.)
torque.
(2) After installing the TPS, the throttle plate
should be closed. If the throttle plate is open, install
the sensor on the other side of the tabs in the socket.
(3) Install throttle body. Refer to Throttle Body in
this section.(4) Attach electrical connectors to idle air control
motor and throttle position sensor.
(5) Install EVAP purge hose to throttle body nip-
ple.
IDLE AIR CONTROL MOTOR
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove throttle body. Refer to Throttle Body in
this section.
(3) Remove electrical connector from idle air con-
trol motor and throttle position sensor.
(4) Remove the EVAP purge hose from the throttle
body.
(5) Remove idle air control motor mounting screws
(Fig. 95).
(6) Remove motor from throttle body. Ensure the
O-ring is removed with the motor.
INSTALLATION
(1) The new idle air control motor has a new
O-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB Idle
Air Control Motor Open/Close Test to retract the
pintle (battery must be connected.)
(2) Carefully place idle air control motor into
throttle body.
(3) Install mounting screws. Tighten screws to 2
N´m (17 in. lbs.) torque.
(4) Connect electrical connector to idle air control
motor and throttle position sensor.
Fig. 93 Throttle Position Sensor and Idle Air Control
Motor
Fig. 94 Throttle Position Sensor Installation
14 - 52 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)