torque DODGE NEON 1999 Service Manual PDF

(18) Install the wiring harness connector (Fig. 19)
on the speed control servo. Then install the routing
clip for the speed control servo wiring harness on the
speed control servo mounting bracket.
Install speed control servo mounting bracket on
body.
(19) Install and securely tighten the 2 bolts (Fig.
18) mounting the bracket for the speed control servo
to the body.
(20) Install the vacuum supply hose on the speed
control servo (Fig. 18).
(21) Install the power distribution center (PDC)
(Fig. 17) on the battery thermogaurd. PDC is install
by pushing straight down on it until the two retain-
ing clips holding it to the thermogaurd are latched to
the thermogaurd.
(22) Connect the negative (ground) cable on the
battery.
(23) Bleed the base brakes and the ABS brakes
hydraulic systems. Refer to Bleeding Base Brake
Hydraulic System in Service Procedures of the Base
Brake Section and Antilock Brakes Hydraulic System
Bleeding Procedure in Service Procedures of the
Antilock Brake Section for the required procedures.
(24) Fill the master cylinder to the proper fill
level.
(25) Road test vehicle to ensure proper operation
of the base and ABS brake systems.
PROPORTIONING VALVES
CAUTION: Proportioning valves should never be
disassembled.
REMOVE
(1) Remove the chassis brake tube nuts (Fig. 32)
from the proportioning valve controlling the rear
wheel of the vehicle which has premature wheel skid.
(2) Remove the proportioning valve from the chas-
sis brake tube (Fig. 32).
INSTALL
(1) Install the proportioning valve in the chassis
brake tube (Fig. 32).
(2) Tighten the 2 chassis brake tube nuts to a
torque of 17 N´m (145 in. lbs.) torque.
(3) Bleed the affected brake line. See Bleeding
Brake System in the Service Procedures section of
the manual for proper bleeding procedure.
MASTER CYLINDER AND POWER BRAKE BOOSTER
If the Master Cylinder or the Power Booster need
to be serviced or replaced, refer to Master Cylinder
or Power Brake Booster in the Removal And Instal-
lation Section in the Base Brake Section of this ser-
vice manual.
CONTROLLER ANTILOCK BRAKES (CAB)
REMOVE
NOTE: To replace the controller antilock brakes
(CAB) on this vehicle, the integrated control unit
(ICU) and CAB need to be removed from the vehicle
as a unit. The CAB can then be separated from the
HCU. Do not attempt to replace the CAB with the
ICU mounted in the vehicle.
(1) Remove the ICU from the vehicle. Refer to ABS
Integrated Control Unit in the Removal And Instal-
lation Section in this group of the service manual for
the removal procedure.
Fig. 31 Torquing Brake Tube Nuts At Master
Cylinder
Fig. 32 Proportioning Valve Location
5 - 86 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(2) Unplug the pump motor wiring harness (Fig.
33) from the CAB.
(3) Remove the 4 bolts (Fig. 34) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 35).
INSTALL
(1) Install the CAB (Fig. 35) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 34)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 33).
(4) Install the ICU. Refer to ABS Integrated Con-
trol Unit in the Removal And Installation Section in
this group of the service manual for the Installation
procedure.
(5) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.(6) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
FRONT WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Unplug speed sensor cable connector (Fig. 36)
from vehicle wiring harness. Remove clip (Fig. 36)
attaching speed sensor cable connector to vehicle
body.
(4) Remove wheel speed sensor head to steering
knuckle attaching bolt (Fig. 37).
(5) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion,
DO NOT USE PLIERS ON SENSOR HEAD.Use
a hammer and a punch and tap edge of sensor ear,
rocking the sensor side to side until free.
(6) Remove the speed sensor cable assembly grom-
mets from the retaining bracket (Fig. 38). Remove
speed sensor cable routing clip from the frame of the
vehicle (Fig. 38).
Fig. 33 Pump Motor To CAB Wiring Harness
Fig. 34 CAB Attaching Bolts
Fig. 35 Remove/Install CAB
PLBRAKES 5 - 87
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Connect the wheel speed sensor cable connector
to the vehicle wiring harness (Fig. 36).
(2) Install the speed sensor cable assembly grom-
mets into the retaining bracket (Fig. 38). Installspeed sensor cable routing clip onto the frame of the
vehicle (Fig. 38).
(3) Install wheel speed sensor to steering knuckle
attaching screw (Fig. 37). Torque the attaching screw
to 7 N´m (60 in. lbs.)
(4) Install the wheel and tire assembly on vehicle.
(5) Road test vehicle to ensure proper operation of
the base and ABS systems.
REAR WHEEL SPEED SENSOR
NOTE: Proper installation of the Wheel Speed Sen-
sor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor
cables as shown in the on car service section of
this manual, may result in contact with moving
parts or over extension of cables, resulting in an
open circuit.
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel from the vehicle.
(3) Unplug speed sensor cable connector from vehi-
cle wiring harness (Fig. 39). Remove clip (Fig. 39)
attaching speed sensor cable connector to vehicle
body.
(4) Remove the speed sensor cable routing bracket
from under rear brake flex hose mounting bracket.
Then remove the speed sensor cable from the routing
clips on the rear brake flex hose and chassis brake
tube.
(5) Remove bolt (Fig. 40) attaching the rear wheel
speed sensor to the disc brake adapter. Then remove
Fig. 36 Speed Sensor Cable To Wiring Harness
Connection
Fig. 37 Front Wheel Speed Sensor Attaching Bolt
Fig. 38 Front Wheel Speed Sensor Cable Routing
Fig. 39 Rear Speed Sensor Connection To Vehicle
Wiring Harness
5 - 88 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

bolt attaching speed sensor cable routing bracket to
rear strut assembly (Fig. 40).
(6) Remove speed sensor head from the disc brake
adapter. If the speed sensor head has seized in the
adapter, DO NOT USE PLIERS ON SENSOR HEAD.
INSTALL
(1) Install wheel speed sensor head into disc brake
adapter (Fig. 40).
(2) Install wheel speed sensor attaching bolt (Fig.
40). Tighten the attaching bolt to a torque of 7 N´m
(60 in. lbs.)
(3) Install the brake flex hose and wheel speed
sensor cable routing bracket on the rear strut
bracket (Fig. 40).
(4) Install wheel speed sensor cable into the rout-
ing clips on the rear brake flex hose and chassis
brake tube.
(5) Plug speed sensor cable connector into vehicle
wiring harness (Fig. 39). Install clip (Fig. 39) attach-
ing speed sensor cable connector to vehicle body.
(6) Install the tire and wheel assembly on vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS systems.
SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
The total indicator runout allowed for both the
front and rear tone wheel measured using a dial indi-
cator is 0.25 mm (.009 in.).
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE
FRONT WHEEL
Minimum Clearance 0.17 mm (0.007 in.)
Maxamum Clearance 1.80 mm (0.072 in.)
REAR WHEEL
Minimum Clearance 0.37 mm (0.015 in.)
Maxamum Clearance 1.50 mm (0.059 in.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To HCU
At HCU Ports.............21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
MASTER CYLINDER:
To Vacuum Booster
Mounting Nut............28N´m(250 in. lbs.)
BRAKE BOOSTER:
To Dash Panel Mounting Nuts . .28 N´m (250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate
Mounting Bolts............13N´m(115in.lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
REAR DISC BRAKE ADAPTER:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts.............22N´m(192 in. lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
To Mounting Bracket Bolts.....28N´m(250 in. lbs.)
Bracket To Frame Rail
Mounting Bolt (Top)........18N´m(160 in. lbs.)
Bracket To Frame Rail
Mounting Bolts (Side)......22N´m(200 in. lbs.)
PARKING BRAKE:
Lever Mounting Nuts.........28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Knuckle Retaining Nut.....217 N´m (160 ft. lbs.)
WHEEL:
Stud Lug Nut........109±150 N´m (80±110 ft. lbs.)
Fig. 40 Speed Sensor Head Mounting And Cable
Routing
PLBRAKES 5 - 89
REMOVAL AND INSTALLATION (Continued)

CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS................... 1
CLUTCH DISC AND COVER APPLICATION.... 2
CLUTCH REPLACEMENT.................. 2
DESCRIPTION AND OPERATION
CLUTCH CABLE......................... 2
CLUTCH PEDAL POSITION SWITCH......... 2
DIAGNOSIS AND TESTING
CLASH±INTO±REVERSE COMPLAINTS....... 6
CLUTCH CHATTER COMPLAINTS........... 6
CLUTCH COVER AND DISC RUNOUT........ 6
CLUTCH DIAGNOSIS..................... 3
CLUTCH PEDAL POSITION SWITCH......... 2
DRIVE PLATE MISALIGNMENT............. 6
REMOVAL AND INSTALLATION
CLUTCH ASSEMBLY...................... 7CLUTCH CABLE......................... 6
CLUTCH PEDAL POSITION SWITCH......... 7
RELEASE BEARING AND FORK............. 9
CLEANING AND INSPECTION
CLEANING PRECAUTIONS................ 10
CLUTCH CONTAMINATION................ 10
ADJUSTMENTS
CLUTCH CABLE........................ 10
CLUTCH PEDAL POSITION SWITCH........ 11
SPECIFICATIONS
TORQUE.............................. 11
SPECIAL TOOLS
CLUTCH.............................. 11
GENERAL INFORMATION
CLUTCH COMPONENTS
NOTE: Neon vehicles produced at the Toluca
assembly plant, in Mexico, have conventional clutch
and flywheel assemblies. Vehicles produced at Bel-
videre assembly plant have modular clutch assem-
blies.
Before beginning clutch service, check the 11th
character of the V.I.N. to determine where it was
produced. The 11th character is ªDº for vehicles
produced at Belvidere, or ªTº for vehicles produced
at Toluca.
For a vehicle produced at Belvidere assembly,
refer to this manual for service information on the
modular clutch assembly. For a vehicle produced at
Toluca assembly, refer to the following information
to determine proper service procedures.
Service parts stock only a Conventional Clutch
Disc Assembly or a Modular Clutch Service Pack-
age to service Toluca built vehicles. The Modular
Clutch Service Package contains the following
parts:
²One modular clutch assembly
²One drive plate assembly
²One backing plate assembly
²Four drive plate to clutch bolts
²Eight drive plate to crankshaft boltsIf only the clutch disc requires replacement,
obtain the clutch disc. Replace the clutch disc
using the information in the Removal And Installa-
tion section of this manual.
If the clutch pressure plate or flywheel requires
replacement, obtain the Modular Clutch Service
Package. Refer to this manual for service informa-
tion on the modular clutch assembly.
The clutch assembly used in this vehicle consists of
a single, dry-type clutch disc and a diaphragm style
clutch cover.
The clutch disc has cushion springs riveted to the
disc hub assembly. The clutch disc facings are riveted
to the cushion springs. The facings are made from a
non-asbestos material.
The clutch cover pressure plate assembly is a dia-
phragm type unit with a one-piece diaphragm spring
with multiple release fingers. The pressure plate
release fingers are preset during manufacture and
are not adjustable.
A sleeve-type release bearing is used to engage and
disengage the clutch cover pressure plate. The bear-
ing is prelubed during manufacture and is a sealed
unit.
The release bearing is operated by a pivoting
release fork in the clutch housing. The fork pivots on
a ball stud within the housing. The release fork is
actuated by a self-adjusting clutch cable.
PLCLUTCH 6 - 1

DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
CLUTCH COVER AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further. If
chatter persists:
(2) Check to see if clutch cable routing is correct
and operates smoothly.
(3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary.
CLASH±INTO±REVERSE COMPLAINTS
Certain NV T350 (A-578) manual transaxles are
equipped with a reverse brake. It prevents clash
when shifting into reverse, but only if the vehicle is
not moving. See Group 21, Transaxle for further
diagnosis.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.
(2) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(3) Check the input shaft spline, clutch disc
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check for broken clutch cover diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Pull up and remove Power Distribution Center.
(2) Remove clutch cable inspection cover.
(3) Pull back on clutch cable housing and disen-
gage cable from housing (Fig. 2).
Fig. 2 Cable at Transaxle
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

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)

(4) Reinstall cable inspection cover and air cleaner
assembly. Check clutch pedal position switch opera-
tion.
CLUTCH PEDAL POSITION SWITCH
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. 8).
SPECIFICATIONS
TORQUE
MODULAR CLUTCH
DESCRIPTION TORQUE
Drive Plate To Clutch Bolts.....75N´m(55ft.lbs.)
Drive Plate To Crankshaft Bolts . .95 N´m (70 ft. lbs.)
Clutch Pedal Pivot Shaft Nut. . . .41 N´m (30 ft. lbs.)
CONVENTIONAL CLUTCH
DESCRIPTION TORQUE
Clutch Cover Bolts...........28N´m(250 in. lbs.)
Flywheel to Crankshaft Bolts. . . .95 N´m (70 ft. lbs.)
Clutch Pedal Pivot Shaft Nut. . . .41 N´m (30 ft. lbs.)
SPECIAL TOOLS
CLUTCH
Clutch Disc Aligner-6724
Fig. 8 Clutch Pedal Position Switch and
Components
PLCLUTCH 6 - 11
ADJUSTMENTS (Continued)

(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.SPECIFICATIONS
NV T350 (A-578) CLUTCH TIGHTENING
REFERENCE
DESCRIPTION TORQUE
Drive Plate To Clutch Bolts....75N´m(55ft.lbs.)
Drive Plate To Crankshaft Bolts . 95 N´m (70 ft. lbs.)
PLCLUTCH 6 - 9
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