engine DODGE NEON 1999 Service Workshop Manual

To disable the ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for proper relay location.
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled
to prevent engine start while performing the follow-
ing tests.
(1) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 2). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp (Fig. 2). Rotate and hold
the ignition switch key in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between the cable clamp and
post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point (Fig.
3). Rotate and hold the ignition switch in the
START position. If voltage reads above 0.2 volt,
correct poor contact at ground cable attaching
point. If voltage reading is still above 0.2 volt after
correcting poor contacts, replace ground cable.
(3) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 4). Hold the ignition switch
key in the START position. If voltage reads above 0.2
volt, correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid (Fig. 5).
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at battery cable to solenoid connec-
tion. If reading is still above 0.2 volt after correct-
ing poor contacts, replace battery positive cable.(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
FEED CIRCUIT TEST
The following procedure will require a suitable
volt-ampere tester (Fig. 6).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 2 Test Battery Connection Resistance
Fig. 3 Test Ground Circuit Resistance
8B - 2 STARTINGPL
DIAGNOSIS AND TESTING (Continued)

(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 7). Refer to the operating instructions
provided with the tester being used.
(2) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location. The 2.5L Diesel Engine, to disable the
engine from starting, disconnect wire connector from
the Fuel Solenoid.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARKposition or with the clutch pedal depressed and SET
parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
6).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps or the Diesel engine
above 450 amps, check for engine seizing or faulty
starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps or Diesel engine above 500 amps,
the problem is the starter. Replace the starter refer
to starter removal.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
Fig. 6 Volt Ampere Tester
Fig. 7 Volt-Ampere Tester Connections
Fig. 4 Test Starter Motor Ground
Fig. 5 Test Battery Positive Cable Resistance
PLSTARTING 8B - 3
DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
ENGAGE.1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position switch
(auto trans) faulty or mis-adjusted.
6. Clutch pedal position switch
(man trans) faulty.
7. Starter solenoid faulty.
8. Starter assembly faulty.1. Refer to Group 8A, Battery. Charge or replace
battery, if required.
2. Refer to Feed Circuit Resistance Test and
Feed Circuit Test in this section.
3. Refer to Relay Test, in this section. Replace
relay, if necessary.
4. Refer to Ignition Switch Test, in Group 8D
Ignition System or Group 8W, Wiring Diagrams.
Replace switch, if necessary.
5. Refer Park/Neutral Position Switch Test, in
Group 21, Transaxle. Replace switch, if
necessary.
6. Refer to Clutch Pedal Position Switch Test, in
Group 6, Clutch. Replace switch, if necessary.
7. Refer to Solenoid Test, in this section.
Replace starter assembly, if necessary.
8. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter assembly faulty.
4. Engine seized.1. Refer to Group 8A, Battery. Charge or replace
battery as necessary.
2. Refer to the Feed Circuit Resistance Test and
the Feed Circuit Test in this section. Repair as
necessary.
3. If all other starting system components and
circuits check OK, replace starter assembly.
4. Refer to Group 9 Engine, for diagnostic and
service procedures.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.1. Broken teeth on starter ring gear.
2. Starter assembly faulty.1. Remove starter. Inspect ring gear and replace
if necessary.
2. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER DOES NOT
DISENGAGE.1. Starter improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter assembly faulty.1. Install starter. Tighten starter mounting
hardware to correct torque specifications.
2. Refer to Relay Test, in this section. Replace
relay, if necessary.
3. Refer to Ignition Switch Test, in Group 8D,
Ignition System. Replace switch, if necessary.
4. If all other starting system components and
circuits check OK, replace starter assembly.
PLSTARTING 8B - 5
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
SAFETY SWITCHES
For Removal and Installation of the:
²Clutch Position Switch, refer to Group 6, Clutch.
²Park/Neutral Switch, refer to Group 21, Tran-
saxle.
STARTER
REMOVAL
(1) Disconnect battery negative cable (Fig. 8).
(2) Raise vehicle.
(3) Vehicles equipped with A/C:
(a) Using a floor jack or jack stand, support the
engine and transmission assembly so they will not
rotate.
(b) Remove the front engine mount bolt from the
insulator and front crossmember mounting bracket
(Fig. 9).
(c) Lower the front of the engine, rotate the
engine forward, allowing easier removal of starter
motor.
(4) For easier servicing, do not remove the wiring
from starter at this time.
(5) Remove two bolts attaching starter to trans-
mission housing (Fig. 10).
(6) Remove starter/starter solenoid assembly from
transmission housing. Position the starter to gain
access to the wiring connectors.
(7) Remove the battery positive cable nut and
remove the battery positive and generator output
wire from the starter (Fig. 11).
(8) Disconnect push-on solenoid connector. Pull
back on slide and push down on rear tab to release
lock.
(9) Position the starter vertically such that the
pinion end faces downward.
(10) Remove the starter through the bottom of the
vehicle. Move aside A/C plumbing as necessary.
INSTALLATION
(1) Clean corrosion/dirt from the cable and wire
terminals before installing wiring to the solenoid.(2) Connect the battery positive and generator out-
put wire to the starter solenoid post (Fig. 11).
CAUTION: It is critical that the generator output ter-
minal be connected to the battery positive terminal
of the starter solenoid, for proper operation of the
charging and cranking systems.
(3) Connect the push-on until fully engaged.
(4) Position the starter face into transmission
housing. Support starter in pilot and start the top
bolt (Fig. 10).
(5) Attach ground cable to lower mounting bolt
and start bolt.
(6) Ensure the proper starter alignment before
tightening the starter mounting bolts to 54 N´m (40
ft. lbs.) torque.
Fig. 9 Front Engine Mount Bolt Removal
Fig. 10 Starter Removal
Fig. 8 Battery Cable Removal and Installation
8B - 6 STARTINGPL

(7) Vehicles equipped with A/C:
(a) Using a floor jack or jack stand, raise the
engine and transmission assembly to the original
position.
(b) Install the front engine mount bolt through
the insulator and front crossmember mounting
bracket (Fig. 9).
(c) Tighten bolt to 54 N´m (40 ft. lbs.) torque.
(8) Lower vehicle and connect battery cables.
STARTER RELAY
The relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for relay location.
SPECIFICATIONS
STARTER
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
TORQUE
DESCRIPTION TORQUE
Starter Mounting Bolts.........54N´m(40ft.lbs.)
Starter Solenoid Battery Nut. . . .10 N´m (90 in. lbs.)
Fig. 11 Wire Connection
Manufacturer BOSCH
Engine Application 2.0L OHC - DOHC
Power rating 0 .95 Kw
Voltage 12 VOLTS
No. of Fields 6
No. of Poles 6
Brushes 4
Drive Planetary Gear Train
Cranking Amperage Draw
test150 - 280 Amps.
PLSTARTING 8B - 7
REMOVAL AND INSTALLATION (Continued)

CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
OVERVIEW............................. 1
DESCRIPTION AND OPERATION
BATTERY TEMPERATURE SENSOR.......... 2
CHARGING SYSTEM OPERATION........... 1
ELECTRONIC VOLTAGE REGULATOR......... 2
GENERATOR............................ 2
DIAGNOSIS AND TESTING
BATTERY TEMPERATURE SENSOR.......... 8
CHARGING SYSTEM RESISTANCE TESTS..... 5CHARGING SYSTEM...................... 2
CURRENT OUTPUT TEST.................. 8
ON-BOARD DIAGNOSTIC SYSTEM TEST..... 10
REMOVAL AND INSTALLATION
BATTERY TEMPERATURE SENSOR......... 11
GENERATOR........................... 10
SPECIFICATIONS
GENERATOR RATINGS................... 12
TORQUE.............................. 12
GENERAL INFORMATION
OVERVIEW
The battery, starting, and charging systems oper-
ate with one another, and must be tested as a com-
plete system. In order for the vehicle to start and
charge properly, all of the components involved in
these systems must perform within specifications.
Group 8A covers the battery, Group 8B covers the
starting system, and Group 8C covers the charging
system. Refer to Group 8W - Wiring Diagrams for
complete circuit descriptions and diagrams. We have
separated these systems to make it easier to locate
the information you are seeking within this Service
Manual. However, when attempting to diagnose any
of these systems, it is important that you keep their
interdependency in mind.
The diagnostic procedures used in these groups
include the most basic conventional diagnostic meth-
ods to the more sophisticated On-Board Diagnostics
(OBD) built into the Powertrain Control Module
(PCM). Use of an induction ammeter, volt/ohmmeter,
battery charger, carbon pile rheostat (load tester),
and 12-volt test lamp may be required.
All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnos-
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects. See the
On-Board Diagnostics Test in Group 8C - Charging
System for more information.
DESCRIPTION AND OPERATION
CHARGING SYSTEM OPERATION
The charging system consists of:
²Generator
²Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
²Ignition switch (refer to Group 8D, Ignition Sys-
tem for information)
²Battery (refer to Group 8A, Battery for informa-
tion)
²Battery temperature sensor
²Voltmeter (refer to Group 8E, Instrument Panel
and Gauges for information)
²Wiring harness and connections (refer to Group
8W, Wiring for information)
The charging system is turned on and off with the
ignition switch. When the ignition switch is turned to
the ON position, battery voltage is applied to the
generator rotor through one of the two field termi-
nals to produce a magnetic field. The generator is
driven by the engine through a serpentine belt and
pulley arrangement.
The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry,
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground.
PLCHARGING SYSTEM 8C - 1

A battery temperature sensor located on the front
bumper beam is used to sense battery temperature.
This temperature data, along with data from moni-
tored line voltage, is used by the PCM to vary the
battery charging rate. This is done by cycling the
ground path to control the strength of the rotor mag-
netic field. The PCM then compensates and regulates
generator current output accordingly and to maintain
the proper voltage depending on battery tempera-
ture.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including the
EVR (field control) circuitry, are monitored by the
PCM. Each monitored circuit is assigned a Diagnos-
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects. See On-
Board Diagnostic System Test in this group for more
information.
GENERATOR
The generator is belt-driven by the engine. It is
serviced only as a complete assembly. If the genera-
tor fails for any reason, the entire assembly must be
replaced.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicle electrical system
through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused
by:
²Worn, loose or defective bearings
²Loose or defective drive pulley
²Incorrect, worn, damaged or misadjusted drive
belt
²Loose mounting bolts
²Misaligned drive pulley
²Defective stator or diode
BATTERY TEMPERATURE SENSOR
The battery temperature sensor is used to deter-
mine the battery temperature. This temperature
data, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
System voltage will be higher at colder temperatures
and is gradually reduced at warmer temperatures.
The sensor is located on the bottom of the battery
tray (Fig. 1).
ELECTRONIC VOLTAGE REGULATOR
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
Operation:The amount of DC current produced
by the generator is controlled by EVR circuitry con-
tained within the PCM. This circuitry is connected in
series with the generators second rotor field terminal
and its ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage and bat-
tery temperature (refer to Battery Temperature Sen-
sor for more information). It then compensates and
regulates generator current output accordingly. Also
refer to Charging System Operation for additional
information.
DIAGNOSIS AND TESTING
CHARGING SYSTEM
When the ignition switch is turned to the ON posi-
tion, battery potential will register on the voltmeter.
During engine cranking a lower voltage will appear
on the meter. With the engine running, a voltage
reading higher than the first reading (ignition in ON)
should register.
The following are possible symptoms of a charging
system fault:
²The voltmeter does not operate properly
²An undercharged or overcharged battery condi-
tion occurs.
Fig. 1 Battery Temperature Sensor
8C - 2 CHARGING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

Remember that an undercharged battery is often
caused by:
²Accessories being left on with the engine not
running
²A faulty or improperly adjusted switch that
allows a lamp to stay on. See Ignition-Off Draw Test
in Group 8A, Battery for more information.
The following procedures may be used to correct a
problem diagnosed as a charging system fault.
INSPECTION
(1) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(2) Inspect all fuses in the fuseblock module and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.(3) Inspect the electrolyte level in the battery.
Replace battery if electrolyte level is low.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in Group 7, Cooling Sys-
tem.
(6) Inspect automatic belt tensioner (if equipped).
Refer to Group 7, Cooling System for information.
(7) Inspect connections at generator field, battery
output, and ground terminals. Also check ground con-
nection at engine. They should all be clean and tight.
Repair as required.
PLCHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)

These tests will show the amount of voltage drop
across the generator output wire from the generator
output (B+) terminal to the battery positive post.
They will also show the amount of voltage drop from
the ground (-) terminal on the generator (Fig. 2) to
the battery negative post.
A voltmeter with a 0±18 volt DC scale should be
used for these tests. By repositioning the voltmeter
test leads, the point of high resistance (voltage drop)
can easily be found.
Test points on the generator may be reached by
either removing the air cleaner housing or below by
raising the vehicle on a hoist.
PREPARATION
(1) Before starting test, make sure battery is in
good condition and is fully-charged. See Group 8A,
Battery for more information.
(2) Check condition of battery cables at battery.
Clean if necessary.
(3) Start the engine and allow it to reach normal
operating temperature.
(4) Shut engine off.
(5) Connect an engine tachometer.
(6) Fully engage the parking brake.
TEST
(1) Start engine.
(2) Place heater blower in high position.
(3) Turn on headlamps and place in high-beam
position.
(4) Turn vehicle interior lamps on.
(5) Start engine. Bring engine speed up to 2400
rpm and hold.
(6) Testing (- ground) circuitry:
(a) Touch the negative lead of voltmeter directly
to battery positivePOST(Fig. 4).
(b) Touch the positive lead of voltmeter to the
B+ output terminal stud on the generator (not the
terminal mounting nut). Voltage should be no
higher than 0.6 volts. If voltage is higher than 0.6
volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. If voltage is
now below 0.6 volts, look for dirty, loose or poor
connection at this point. Refer to Group 8, Wiring
for connector location. A voltage drop test may be
Fig. 2 Generator Terminals
Fig. 3 Electrical Resistance Test
Fig. 4 Battery Voltage Test
PLCHARGING SYSTEM 8C - 7
DIAGNOSIS AND TESTING (Continued)

performed at each (- ground) connection in this cir-
cuit to locate the excessive resistance.
(7) Testing (+ positive) circuitry:
(a) Touch the positive lead of voltmeter directly
to battery negativePOST.
(b) Touch the negative lead of voltmeter to the
ground terminal stud on the generator case (not
the terminal mounting nut). Voltage should be no
higher than 0.3 volts. If voltage is higher than 0.3
volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. If voltage is
now below 0.3 volts, look for dirty, loose or poor
connection at this point. A voltage drop test may be
performed at each (+ positive) connection in this
circuit to locate the excessive resistance. This test
can also be performed between the generator case
and the engine. If test voltage is higher than 0.3
volts, check for corrosion at generator mounting
points or loose generator mounting.
CURRENT OUTPUT TEST
The current output test will determine if the
charging system can deliver its minimum test cur-
rent (amperage) output. Refer to the Specifications
section at the end of this group for minimum test
current (amperage) requirements.
The first part of this test will determine the com-
bined amperage output of both the generator and the
Electronic Voltage Regulator (EVR) circuitry.
PREPARATION
(1) Determine if any Diagnostic Trouble Codes
(DTC) exist. To determine a DTC, refer to On-Board
Diagnostics in this group. For repair, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual.
(2) Before starting test, make sure battery is in
good condition and is fully-charged. See Group 8A,
Battery for more information.
(3) Check condition of battery cables at battery.
Clean if necessary.
(4) Perform the Voltage Drop Test. This will
ensure clean and tight generator/battery electrical
connections.
(5) Be sure the generator drive belt is properly
tensioned. Refer to Group 7, Cooling System for
information.
(6) A volt/amp tester equipped with both a battery
load control (carbon pile rheostat) and an inductive-
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied
with tester. When using a tester equipped with an
inductive-type clamp, removal of wiring at the gener-
ator will not be necessary.
(7) Start the engine and allow it to reach operating
temperature.
(8) Shut engine off.(9) Turn off all electrical accessories and all vehicle
lighting.
(10) Connect the volt/amp tester leads to the bat-
tery. Be sure the carbon pile rheostat control is in the
OPEN or OFF position before connecting leads. See
Load Test in Group 8A, Battery for more information.
Also refer to the operating instructions supplied with
test equipment.
(11) Connect the inductive clamp (ammeter probe).
Refer to the operating instructions supplied with test
equipment.
(12) If volt/amp tester is not equipped with an
engine tachometer, connect a separate tachometer to
the engine.
TEST
(1) Perform the previous test Preparation.
(2) Fully engage the parking brake.
(3) Start engine.
(4) Bring engine speed to 2500 rpm.
(5) With engine speed held at 2500 rpm, slowly
adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment.On
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment.
(6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera-
tor Ratings chart. This can be found in the Specifica-
tions section at the end of this group. A label stating
a part reference number is attached to the generator
case. On some engines this label may be located on
the bottom of the case. Compare this reference num-
ber to the Generator Ratings chart.
(7) Rotate the load control to the OFF position.
(8) Continue holding engine speed at 2500. If EVR
circuitry is OK, amperage should drop below 15±20
amps. With all electrical accessories and vehicle
lighting off, this could take several minutes of engine
operation. If amperage did not drop, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual for testing.
(9) Remove volt/amp tester.
If minimum amperage could not be met, refer to
the appropriate Powertrain Diagnostic Procedures
manual for testing.
BATTERY TEMPERATURE SENSOR
To perform a complete test of this sensor and its
circuitry, refer to the appropriate Powertrain Diag-
nostic Procedures manual. To test the sensor only,
refer to the following:
(1) The sensor is located under the battery and is
attached to the battery tray (Fig. 5). A two-wire pig-
8C - 8 CHARGING SYSTEMPL
DIAGNOSIS AND TESTING (Continued)