check engine DODGE NEON 1999 Service Workshop Manual

parking lamps out put. Press the panic button and
check for a voltage pulse (Fig. 2).
(2) If no voltage pulse is measured, replace the
receiver. If voltage OK, repair circuit to the parking
lamps as necessary.
(3) Connect the meter to Pin 5 of the black connec-
tor and to ground to test head lamps out put. Press
the panic button and check for a voltage pulse (Fig.
2).
(4) If no voltage pulse is measured, replace the
receiver. If voltage OK, repair circuit to the head
lamps as necessary.
REMOTE KEYLESS ENTRY SYSTEM
When trouble shooting problems with the Remote
Keyless Entry System, always verify that the power
door lock/unlock switches are functional. If the doors
do not lock/unlock refer to Group 8W, Wiring Dia-
gram for Pin and wiring locations.
If the following items do not work:
²Remote keyless entry system
²Radio/clock
²Door lock switches
A blown fuse is the probable cause. Check fuses 2,
3 and 11 in the fuse block. To check for a blown fuse,
pull the fuse out slightly, but maintain contact
between the fuse terminals and the terminals in fuse
block. Using the voltmeter probe, check both termi-
nals for 12 volts. If only one terminal measures bat-
tery voltage, the circuit breaker is defective and must
be replaced. If neither terminal measures battery
voltage, check the high current fuses 3 and 11 in the
Power Distribution Center (PDC). The PDC is located
in the engine compartment. If fuse(s) are NOT OK,
replace fuse(s) or repair as necessary. If fuses are
OK, check for an open or shorted circuit to the Power
Distribution Center, repair as needed.
SERVICE PROCEDURES
HORN CHIRP CANCELLATION
During the programming operation the horn chirp
can be disabled or enable using the following proce-
dure. One or both transmitters can be program to be
disabled or enable.
(1) Retrieve the programming line from the upper
edge of the passenger side cowl trim panel upper
edge. The RKE Programming Line is a green wire
with a red bullet connector.
(2) Using a jumper wire, ground the RKE pro-
gramming line.
(3) Turn ignition switch to the ON position.
(4) Press any button on the transmitter. The locks
will cycle to confirm programming,
(5) To disable or enable horn chirp press the lock
button on the transmitter four times and the hornwill sound to confirm programming. Press the lock
button on the second transmitter four times and the
horn will sound to confirm programming.
(6) Disconnect the programming line from ground.
This returns the system to its normal operation
mode.
(7) Replace any removed components. Return pro-
gramming line chirpto its original position. Check for
system operation.
PANIC FUNCTION CANCELLATION
During the programming operation the panic func-
tion can be disabled or enable using the following
procedure. One or both transmitters can be program
to be disabled or enable.
(1) Retrieve the programming line from the upper
edge of the passenger side cowl trim panel. The RKE
Program Line is a green wire with a red bullet con-
nector.
(2) Using a jumper wire, ground the RKE Pro-
gramming Line.
(3) Turn ignition switch to the ON position.
(4) Press any button on the transmitter. The locks
will cycle to confirm programming,
(5) To disable or enable panic function press the
panic button on the transmitter four times and the
horn will sound to confirm programming. Press the
panic button on the second transmitter four times
and the horn will sound to confirm programming.
(6) Disconnect the programming line from ground.
This returns the system to its normal operation
mode.
(7) Replace any removed components. Return the
programming line to its original position. Check for
system operation.
PROGRAM REMOTE KEYLESS ENTRY MODULE
(1) Retrieve the programming line from the upper
edge of the passenger side cowl trim panel. The RKE
Programming Line is a green wire with a red bullet
connector.
(2) Using a jumper wire, ground the RKE pro-
gramming line.
(3) Turn ignition switch to the ON position.
(4) Press any button on the transmitter to set
code. The locks will cycle to confirm programming. If
there is a second transmitter it must be set at this
time. Press any button on the second transmitter and
wait for the locks to cycle to confirm programming.
(5) Disconnect the programming line from ground.
This returns the system to its normal operation
mode.
(6) Replace all removed components. Return pro-
gramming line to its original position. Check for sys-
tem operation.
PLPOWER DOOR LOCKS 8P - 5
DIAGNOSIS AND TESTING (Continued)

TERMINOLOGY
This a list of terms with there definitions used in
the wiring diagrams.
Built-Up-Export...........Vehicles Built For Sale
In Markets Other Than North America
Except-Built-Up-Export.....Vehicles Built For Sale
In North America
LHD..................Left Hand Drive Vehicles
RHD.................Right Hand Drive Vehicles
ATX . . . .Automatic Transmission-Front Wheel Drive
MTX .....Manual Transmission-Front Wheel Drive
AT......Automatic Transmission-Rear Wheel Drive
MT .......Manual Transmission-Rear Wheel Drive
SOHC............Single Over Head Cam Engine
DOHC.............Dual Over Head Cam Engine
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located on theengine com-
partment harnessareC100series numbers.
²Connectors located on theinstrument panel
harnessareC200series numbers.
²Connectors located on thebody harnessare
C300series numbers.
²Jumper harness connectorsareC400series
numbers.
²Grounds and ground connectorsare identi-
fied with aªGºand follow the same series number-
ing as the in-line connector.
Component connectors are identified by the compo-
nent name instead of a number (Fig. 2). Multiple
connectors on a component use a C1, C2, etc. identi-
fier (Fig. 3).
LOCATIONS
Section 8W-90 contains connector/ground location
illustrations. The illustrations contain the connector
name (or number)/ground number and component
identification. Connector/ground location charts in
Section 8W-90 reference the illustration number for
components and connectors.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the Dia-
gram pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
Fig. 2 Component Identification
Fig. 3 Connector Identification
PL8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)

WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 4) is used to indicate this. When han-
dling any component with this symbol comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective
packing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: - Most of the electrical components used
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10-
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
Fig. 4 Electrostatic Discharge Symbol
8W - 01 - 8 8W - 01 GENERAL INFORMATIONPL
DESCRIPTION AND OPERATION (Continued)

C277C13C2CLUSTER INSTRUMENT
8611C103
G12
22
TN/BK
G12
20
TN/BK
G21
22
GY/LB
G21
20
GY/LB
G3
22
BK/PK
G3
20
BK/PK
951
SWITCH PRESSURE
HIGH
A/C
G3
20
BK/PKC20
18
BR/OR
C20
20
BR/OR
1
2
13C160
RELAY FAN
STATE
SOLID
GENERATOR
K173
20
DG
K173
20
LGC28
18
DB/ORK20
18
DG
C15673C18C238C218C264C14C2
GENERATOR
LAMP
DRIVERTACHOMETER
SIGNALCHECK
ENGINE
LAMP
DRIVERA/C
SWITCH
SENSERADIATOR
FAN
PULSE
CONTROLA/C
COMPRESSOR
CLUTCH
RELAY
CONTROLGENERATOR
FIELD
DRIVER
MODULE CONTROL
POWERTRAIN (IN PDC) RELAY
CLUTCH
COMPRESSOR
A/C
A/C
SWITCH
SIGNAL
RELAY
CONTROL CHECK
ENGINE
LAMP TACHOMETER GENERATOR
LAMP
36
(8W-40-5)
(8W-40-6)
(8W-40-8)
(8W-42-5)
(8W-42-5)
(8W-20-2) (8W-42-2)
8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEMPL
J988W-18259

ST-RUN A21FUEL
LEVEL
SENSOR
SIGNAL
INSTRUMENT
CLUSTER
G5
20
DB/WT
G5
20
DB/WT
G5
20
DB/WT
G20
22
VT/YL
G20
20
VT/YL
G20
20
VT/YL
G4
20
DB
Z3
16
BK/OR
Z3
14
BK/OR
G6
22
GY
G6
20
GY
G6
18
GY
S201
SWITCH PRESSURE
OIL
ENGINE
S219BLOCK FUSE
G4
20
DB
G204
8C161
4C103
1C28C1
5C230
3C160
23
10C25C1
1
11
31
POWERTRAIN
CONTROL
MODULE
FUEL
PUMP
MODULESENSOR TEMPERATURE
COOLANT
ENGINE
3G4
18
DB
C1609
C10311
BK/PK20 G3
BK/PK22 G3
BK/PK20 G3
MODULE CONTROL
POWERTRAIN
8
3C2
CHECK
ENGINE
LAMP
DRIVER
3
6
C160
7C103
4C2
RKEOTHER
5A FUSE
11
SENSOR
SIGNAL
ENGINE
COOLANT
TEMPERATURE
GAUGE LAMP ENGINE
CHECK
FUEL
GAUGE
LAMP PRESSURE
OIL
LOW FUEL
LEVEL
SENSOR
SIGNAL
C2
C2
C1056
DB20 G4
(8W-10-9)
(8W-11-15)
(8W-11-16)
(8W-30-12)(8W-30-7)
(8W-30-11)(8W-30-11)
(8W-15-10)
(8W-15-11)(8W-11-2)
(8W-11-3)
(8W-11-4)
(8W-11-15)
(8W-15-10)
(8W-15-11)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTERPL
J988W-18274

CAV CIRCUIT FUNCTION
1 M2 20YL* DOOR LIFT GROUND SWITCH
2 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
2 L3 16RD/OR** DIMMER SWITCH HIGH BEAM OUTPUT
3 L60 22TN RIGHT TURN SIGNAL
4 G10 20LG/RD SEAT BELT SWITCH SENSE
5 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
6 M1 22PK FUSED B(+)
7 G21 22GY/LB TACHOMETER SIGNAL
8 Z3 16BK/OR GROUND
9 R41 18BK/TN AIRBAG WARNING LAMP DRIVER
10 G7 22WT/OR VEHICLE SPEED SENSOR SIGNAL
BLACK
51
10 6
** RKE
CAV CIRCUIT FUNCTION
1 G6 22GY OIL PRESSURE SWITCH SENSE
2 G19 22LG/OR ABS WARNING LAMP DRIVER
3 G3 22BK/PK CHECK ENGINE LAMP DRIVER
4 G20 22VT/YL ECT GAUGE SENSOR SIGNAL
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 G9 22GY/BK RED BRAKE WARNING LAMP DRIVER
7 G12 22TN/BK GENERATOR LAMP DRIVER
8 L61 22LG LEFT TURN SIGNAL
9 E2 22OR PANEL LAMPS DRIVER
10 G4 20DB FUEL LEVEL SENSOR SIGNAL
BLACK
51
10 6
INSTRUMENT
CLUSTER - C1
CLUSTER - C2INSTRUMENT
* LHD
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTSPL
J988W-1PL008024

CAV CIRCUIT FUNCTION
1- -
2 K19 18BK/GY IGNITION COIL NO. 1, 3 DRIVER
3 K17 18DB/TN IGNITION COIL NO. 2, 4 DRIVER
4 K20 18DG GENERATOR FIELD DRIVER
5 V32 20YL/RD SPEED CONTROL FEED
6 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
8 G3 20BK/PK CHECK ENGINE LAMP DRIVER
9- -
10 Z12 18BK/TN GROUND
11 - -
12 - -
13 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
14 - -
15 - -
16 K14 18LB/BR
17 K12 18TN
18 K173 20LG
19 - -
20F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
21 - -
22 - -
23 G4 20DB FUEL LEVEL SENSOR SIGNAL
24 K42 20BK/LG** KNOCK SENSOR SIGNAL
24 K42 20DB/LG** KNOCK SENSOR SIGNAL
31 40
21 30
11 20
110
BLACK
CONTROL SOLENOID RECIRCULATION GAS EXHAUST 20GY/YL K35 40- - 39
SENSE SWITCH A/C 18BR/OR C20 38
SIGNAL SENSOR POSITION THROTTLE 20OR/DB K22 35
- - 34
SIGNAL SENSOR POSITION CAMSHAFT 20TN/YL K44 33
SIGNAL SENSOR POSITION CRANKSHAFT 20GY/BK K24 32
- - 31
SIGNAL SENSOR OXYGEN HEATED UPSTREAM 20BK/DG K41 30
- - 29
- - 28
- - 27
SIGNAL SENSOR TEMPERATURE COOLANT ENGINE 20TN/BK** K2 26
SIGNAL SENSOR TEMPERATURE COOLANT ENGINE 20TN/DB* K2 26
- - 25
POWERTRAIN
CONTROL
MODULE - C2
20DB/WT F12 (ST-RUN)OUTPUT SWITCH IGNITION FUSED
24K42 20DB/LG KNOCK SENSOR SIGNAL
* 1.8L/2.0L SOHC
** 2.0L DOHC
1.8L
2.0L 36 K1 20DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
FUEL INJECTOR NO. 4 DRIVER
FUEL INJECTOR NO. 2 DRIVER
SOLID STATE RELAY CONTROL
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTSPL
J988W-1PL008034

ENGINE
CONTENTS
page page
2.0L DOHC ENGINE...................... 58
2.0L SOHC ENGINE...................... 12ENGINE DIAGNOSIS....................... 7
STANDARD SERVICE PROCEDURES.......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION
CHECKING ENGINE OIL LEVEL.............. 5
CRANKSHAFT SPROCKET BOLT ACCESS
PLUG................................ 2
ENGINE CORE PLUGS.................... 2
ENGINE OIL SERVICE..................... 5
ENGINE PERFORMANCE.................. 2FORM-IN-PLACE GASKETS................. 1
HONING CYLINDER BORES................ 3
HYDROSTATIC LOCKED ENGINE............ 4
MEASURING MAIN BEARING AND
CONNECTING ROD BEARING CLEARANCES . 3
REPAIR OF DAMAGED OR WORN THREADS . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Silicone Rubber Adhesive Sealant and MopartGas-
ket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtSILICONE RUBBER ADHESIVE
SEALANT
MopartSilicone Rubber Adhesive Sealant or equiv-
alent, normally black in color, is available in three
ounce tubes. Moisture in the air causes the Mopart
Silicone Rubber Adhesive Sealant material to cure.
This material is normally used on flexible metal
flanges. It has a shelf life of one year and will not
properly cure if over age. Always inspect the package
for the expiration date before use.MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtTORQUE CURE GASKET MAKER
MopartTorque Cure Gasket Maker is a unique
anaerobic type gasket material to be usedONLY
between the bedplate and engine block. The material
cures in the absence of air when torqued between
two metallic surfaces. It will not cure if left in the
uncovered tube. This anaerobic material is specially
made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces
removing all loose material. Inspect stamped parts to
PLENGINE 9 - 1

assure gasket rails are flat. Flatten rails with a ham-
mer on a heavy steel plate if required. Gasket sur-
faces must be free of oil and dirt. Make sure old
gasket material is removed from blind attaching
holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 inch.) diameter or less of seal-
ant to one gasket surface. Be certain the material
surrounds each mounting hole. Excess material can
easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
The MopartSilicone Rubber Adhesive Sealant gas-
ket material or equivalent should be applied in a con-
tinuous bead approximately 3 mm (0.120 inch) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.)
drop is placed in the center of the gasket contact
area. Uncured sealant may be removed with a shop
towel. Components should be torqued in place while
the sealant is still wet to the touch (within 10 min-
utes). The usage of a locating dowel is recommended
during assembly to prevent smearing material off the
location.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmly
with pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is atleast 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINEPL
GENERAL INFORMATION (Continued)

HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes, using a light honing oil.Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 2).
(4) A controlled hone motor speed between
200-300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50-60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
ENGINE WITH 5 MAIN BEARINGS
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & 3
main bearing.
²When checking #3 main bearing shim #2 & 4
main bearing.
²When checking #4 main bearing shim #3 & 5
main bearing.
²When checking #5 main bearing shim #4 main
bearing.
ENGINE WITH 4 MAIN BEARING
²When checking #1 main bearing shim # 2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
PLENGINE 9 - 3
GENERAL INFORMATION (Continued)