key DODGE NEON 1999 Service Manual PDF

FUEL INJECTORSÐPCM OUTPUT
The 2.0L engine uses electrically operated top feed
fuel injectors (Fig. 26). The Automatic Shutdown
(ASD) relay supplies battery voltage to the fuel injec-
tors. The PCM controls the ground path for each
injector in sequence. By switching the ground paths
on and off, the PCM fine-tunes injector pulse width.
Injector pulse width refers to the amount of time an
injector operates.
The PCM determines injector synchronization from
the camshaft position sensor and crankshaft position
sensor inputs. The PCM grounds the ASD and fuel
pump relays after receiving the camshaft position
sensor and crankshaft position sensor inputs.
The PCM energizes the injectors in a sequential
order during all engine operating conditions except
start-up. For the first injector pulse width during
start-up, all injectors are energized at the same time.
Once the PCM determines crankshaft position, it
begins energizing the injectors in sequence.
IGNITION COILÐPCM OUTPUT
The coil assembly consists of 2 coils molded
together. The coil assembly is mounted over the valve
cover (Fig. 27) or (Fig. 28). High tension leads route
to each cylinder from the coil. The coil fires two
spark plugs every power stroke. One plug is the cyl-
inder under compression, the other cylinder fires on
the exhaust stroke. Coil number one fires cylinders 1
and 4. Coil number two fires cylinders 2 and 3. The
PCM determines which of the coils to charge and fire
at the correct time.
The Auto Shutdown (ASD) relay provides battery
voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When
the PCM breaks the contact, the energy in the coil
primary transfers to the secondary causing the
spark. The PCM will de-energize the ASD relay if it
does not receive the crankshaft position sensor andcamshaft position sensor inputs. Refer to Auto Shut-
down (ASD) RelayÐPCM Output in this section for
relay operation.
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT
The PCM supplies the malfunction indicator (check
engine) lamp on/off signal to the instrument panel
through the CCD Bus. The CCD Bus is a communi-
cations port. Various modules use the CCD Bus to
exchange information.
The Check Engine lamp comes on each time the
ignition key is turned ON and stays on for 3 seconds
as a bulb test.
The Malfunction Indicator Lamp (MIL) stays on
continuously, when the PCM has entered a Limp-In
mode or identified a failed emission component. Dur-
ing Limp-in Mode, the PCM attempts to keep the
system operational. The MIL signals the need for
immediate service. In limp-in mode, the PCM com-
pensates for the failure of certain components that
Fig. 26 Fuel Injector
Fig. 27 Ignition Coil PackÐSOHC
Fig. 28 Ignition Coil PackÐDOHC
14 - 34 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

(7) Attach the other end of the jumper wire to
relay terminal 86. This activates the relay. The ohm-
meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.
(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the ASD
and fuel pump relay circuits. Refer to group 8W, Wir-
ing Diagrams.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition for Diagnosis and Test-
ing of Camshaft and Crankshaft Sensors.
ENGINE COOLANT TEMPERATURE SENSOR
(1) With the key off, disconnect wire harness con-
nector from coolant temperature sensor (Fig. 79) or
(Fig. 80).(2) Connect a high input impedance (digital) volt-
ohmmeter to terminals A and B (Fig. 81). The ohm-
meter should read as follows:
²Engine/Sensor at normal operating temperature
around 200ÉF should read approximately 700 to
1,000 ohms.
²Engine/Sensor at room temperature around 70ÉF
ohmmeter should read approximately 7,000 to 13,000
ohms.
(3) T
est the resistance of the wire harness between
the PCM 60-way connector terminal 28 and the sensor
harness connector. Also check for continuity between
PCM 60-way connector terminal 51 and the sensor har-
ness connector. Refer to Group 8W, Wiring diagrams for
circuit information. If the resistance is greater than 1
ohm, repair the wire harness as necessary.
HEATED OXYGEN SENSOR
Use an ohmmeter to test the heating element of
the oxygen sensors. Disconnect the electrical connec-
tor from each oxygen sensor. The white wires in the
sensor connector are the power and ground circuits
for the heater. Connect the ohmmeter test leads to
terminals of the white wires in the heated oxygen
sensor connector. Replace the heated oxygen sensor if
the resistance is not between 4 and 7 ohms.
IDLE AIR CONTROL (IAC) MOTOR TEST
To preform a complete test of IAC motor and its
circuitry, refer to DRB scan tool and the appropriate
Powertrain Diagnostics Procedures manual.
KNOCK SENSOR
The engine knock sensor is affected by a number of
factors. A few of these are: ignition timing, cylinder
pressure, fuel octane, etc. The knock sensor generates
an AC voltage whose amplitude increases with the
increase of engine knock. The knock sensor can be
tested with a digital voltmeter. The RMS voltage starts
Fig. 79 Engine Coolant Temperature Sensor
LocationÐSOHC
Fig. 80 Engine Coolant Temperature Sensor
LocationÐDOHC
Fig. 81 Engine Coolant Temperature Sensor
PLFUEL SYSTEM 14 - 47
DIAGNOSIS AND TESTING (Continued)

at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls
outside of this range a DTC will be set.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
To perform a complete test of the MAP sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(1) Test the MAP sensor output voltage at the
MAP sensor connector between terminals 1 and 4
(Fig. 82). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts.
The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If
not OK, go to step 3.
(2) Test PCM terminal 36 for the same voltage
described in the previous step to verify wire harness
condition. Repair as required.
(3) Test the MAP sensor ground circuit at sensor
connector terminal 1 and PCM terminal 43. If OK, go
to next step. If not OK, repair as required.
(4) Test MAP sensor supply voltage between sen-
sor connector terminals 3 and 1 with the key ON.
The voltage should be approximately 5 volts (6.5V).
Five volts (6.5V) should also be at terminal 61 of the
PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
THROTTLE POSITION SENSOR
To perform a complete test of the this sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the throttle position sensor only, refer to the fol-
lowing:
The Throttle Position Sensor (TPS) can be tested
with a digital voltmeter (DVM). The center terminal
of the sensor is the output terminal. One of the other
terminals is a 5 volt supply and the remaining ter-
minal is ground.
Connect the DVM between the center and sensor
ground terminal. Refer to Group 8W - Wiring Dia-
grams for correct pinout.
With the ignition switch in the ON position, check
the output voltage at the center terminal wire of the
connector. Check the output voltage at idle and at
Wide-Open-Throttle (WOT). At idle, TPS output volt-
age should be approximately 0.38 volts to 1.2 volts.
At wide open throttle, TPS output voltage should be
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
THROTTLE BODY MINIMUM AIR FLOW
(1) Turn ignition key to Off.
(2) Disconnect the PCV valve hose from the intake
manifold nipple (Fig. 83). Cap the PCV vacuum nip-
ple.
(3) Disconnect purge hose from the nipple on the
throttle body (Fig. 84).
(4) Use a piece of hose to attach Air Metering Ori-
fice 6457 (0.125 in. orifice) to the purge nipple on the
throttle body (Fig. 85).
(5) Ensure that all accessories are off.
Fig. 82 MAP Sensor Connector
Fig. 83 PCV Vacuum Nipple
14 - 48 FUEL SYSTEMPL
DIAGNOSIS AND TESTING (Continued)

STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION
STEERING COLUMN ASSEMBLY............ 35
STEERING GEAR TO STEERING
COLUMN COUPLING................... 36
DIAGNOSIS AND TESTING
STEERING COLUMN TO STEERING
GEAR COUPLING...................... 36
STEERING COLUMN..................... 36REMOVAL AND INSTALLATION
STEERING COLUMN SERVICE
PROCEDURE WARNINGS............... 37
STEERING COLUMN..................... 38
SPECIFICATIONS
STEERING COLUMN FASTEER
TORQUE SPECIFICATIONS.............. 42
DESCRIPTION AND OPERATION
STEERING COLUMN ASSEMBLY
Both the standard non-tilt and tilt steering col-
umns (Fig. 1) have been designed to be serviced only
as complete assemblies, if a component of the steer-
ing column is defective. The only replaceable compo-nents of the steering column assembly, are the key
cylinder, ignition switch, multi- function switch, clock
spring, trim shrouds and steering wheel. These
replaceable components of the steering column can be
serviced without requiring removal of the steering
column from the vehicle.
Fig. 1 Non-Tilt And Tilt Steering Column Assemblies
PLSTEERING 19 - 35

WARNING: WHEN HANDLING AN UNDEPLOYED
AIR BAG MODULE DURING SERVICING OF THE
STEERING COLUMN THE FOLLOWING PRECAU-
TIONS SHOULD BE OBSERVED. AT NO TIME
SHOULD ANY SOURCE OF ELECTRICITY BE PER-
MITTED NEAR THE INFLATOR ON THE BACK OF
THE AIR BAG MODULE. WHEN CARRYING A LIVE
MODULE, THE TRIM COVER SHOULD BE POINTED
AWAY FROM THE BODY TO MINIMIZE INJURY IF
MODULE ACCIDENTLY DEPLOYS. IF AIR BAG MOD-
ULE IS PLACED ON A BENCH OR OTHER SUR-
FACE, PLASTIC COVER SHOULD BE FACE UP TO
MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL
DEPLOYMENT.
(7) Remove air bag module from center of steering
wheel. Then disconnect the clock spring electrical
lead from the back of the air bag module (Fig. 10).
(8) Disconnect the wiring lead for the horn switch
in the airbag module from the wiring lead coming
from the clockspring (Fig. 11).
(9) Turn the lock cylinder to theoffposition and
remove the key from the lock cylinder
(10) Turn the steering wheel to the left 1/2 a turn
(180É) until the steering column lock is engaged (Fig.
12).
(11) Remove the steering wheel retaining nut,
from the steering column shaft (Fig. 12). If equipped,
remove the damper weight from the steering wheel.
CAUTION: When installing wheel puller on the
steering wheel be sure puller bolts are fully seated
in the threaded holes on the steering wheel. If bolts
are not fully seated in the threaded holes, the
threads may be stripped out of the steering wheel
when removing the steering wheel.
(12) Install Puller, Snap-On CJ2001P or an equiv-
alent on the steering wheel (Fig. 13).CAUTION: Do not bump or hammer on steering
wheel or steering column shaft when removing
steering wheel from steering column.
Fig. 11 Clock Spring To Horn Switch Wiring
Connection
Fig. 12 Steering Wheel Attaching Nut
Fig. 13 Steering Wheel Puller Installed
Fig. 10 Air Bag Module Electrical Connection
PLSTEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)

(13) Remove steering wheel assembly from steer-
ing column shaft using Puller, Special Tool C-3428-B
or equivalent.
(14) Remove key lock cylinder from steering col-
umn. Key lock cylinder is removed from steering col-
umn using the following procedure. Place the key
lock cylinder in the Run position. Then through the
hole in lower shroud, (Fig. 14) depress lock cylinder
retaining tab and remove key lock cylinder.
(15) Remove the 3 screws attaching the upper and
lower shroud to the steering column (Fig. 15). First
remove lower shroud from steering column, then
release tilt lever and tilt steering column to its low-
est point. Then remove upper shroud from steering
column.
(16) Remove retaining pin from pinch bolt in steer-
ing column upper coupling (Fig. 16).
(17) Loosen the steering column upper coupling
pinch bolt retaining nut and remove pinch bolt (Fig.
16) from steering coupling.(Pinch bolt nut iscaged to coupler and is not removable.)Then
separate steering column shaft coupling from lower
steering coupling.
(18) Remove the 2 nuts attaching the lower
mounting bracket of the steering column to the steer-
ing column mounting bracket.
(19) Remove the 2 nuts mounting the steering col-
umn upper bracket to the steering column support
bracket (Fig. 17).
(20) Lower steering column in the steering column
access opening of the lower instrument panel.
(21) Remove routing clip (Fig. 18) holding wiring
harness to jacket of steering column. Then remove
wiring harness connectors from the multi- function
switch and the windshield wiper switch (Fig. 18).
(22) Remove the vehicle wiring harness connec-
tors from the ignition switch and clock spring (Fig.
19).
Fig. 14 Key Lock Cylinder Access Hole In Steering
Column Shrouds
Fig. 15 Upper And Lower Steering Column Shrouds
Fig. 16 Upper To Lower Steering Column Coupler
Disassembly
Fig. 17 Steering Column Upper Support Bracket
Attaching Nuts
19 - 40 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: Do not install steering wheel onto shaft
of steering column assembly by driving it onto the
shaft. Pull steering wheel down onto steering col-
umn shaft using ONLY the steering wheel retaining
nut.
(13) Feed clock spring wiring leads through hole in
steering wheel (Fig. 20). Position steering wheel on
shaft of steering column assembly, making sure to fit
flats on hub of steering wheel with formations on
inside of clockspring.
(14) Install steering wheel to steering column
shaft retaining nut and tighten until steering wheel
is fully installed on shaft. The tighten steering wheel
retaining nut to a torque of 61 N´m (45 ft. lbs.).
(15) Connect the clockspring electrical leads to
components such as horn switches and speed control
switches located in the steering wheel (Fig. 11).
(16) Install air bag electrical lead from clock
spring, into connector on back of air bag module (Fig.
10).Be sure electrical connector from clock-
spring is securely latched into air bag module
connector.
CAUTION: The fasteners, screws, and bolts, origi-
nally used for the air bag components are specifi-
cally designed for the air bag system. They must
never be replaced with any substitutes. Anytime a
new fastener is needed, replace only with correct
fasteners provided in service packages or fasteners
listed in the parts book.
(17) Install air bag module into center of steering
wheel. Align air bag module mounting holes with bolt
holes in steering wheel. Installonly the 2 original
or correct replacementair bag module attachingbolts (Fig. 9). Torque the 2 air bag module attaching
bolts to 10 N´m (90 in. lbs.).
(18) Install key lock cylinder into lock housing.
Key lock cylinder is installed by positioning key cyl-
inder in the run position so retaining tab can be
depressed and the pushing key cylinder into lock hos-
ing until retaining tab locks into key lock cylinder.
(19) Reconnect ground cable to Negative post of
the battery.When reconnecting battery on a
vehicle that has had the air bag module
removed, the following procedure should be
used.
²Remove forward console or cover as necessary.
²Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
²Turn ignition key to ON position. Exit vehicle
with the DRB II. Install the latest version of the
proper diagnostic cartridge into the DRB II.
²Ensuring that their are no occupants in the
vehicle, connect negative cable to negative post of the
battery.
²Using the DRB II read and record active fault
codes. Also read and record any stored fault codes.
Refer to the Passive Restraint Diagnostic Test Man-
ual if any faults are found.
²Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
²From the passenger side of the vehicle, turn
ignition key to OFF and then ON observing instru-
ment cluster air bag lamp. It should go on for six to
eight seconds, then go out. This will indicate that the
air bag system is functioning normally.
(20)If air bag warning lamp fails to light,
blinks on and off or goes on and stays on, there
is an air bag system malfunction.Refer to the
Passive Restraint Diagnostic Test Manual to diag-
nose the system malfunction.
(21) Test the operation of the horn, lights and any
other functions that are steering column operated. If
applicable reset the radio and the clock.
(22) Road test vehicle to ensure proper operation
of the steering system and the speed control system.
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
Steering Wheel
Retaining Nut...............61N´m(45ft.lbs.)
Steering Column Assembly
Upper And Lower Mounting Bracket
Attaching Nuts...........17N´m(150 in. lbs.)
Fig. 20 Steering Wheel Installation
19 - 42 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with theU
facing upward.
(2) Install springs into hub slot (Fig. 114).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 115).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 116).
(6) Line up stop ring tang over the keys in the hub
(Fig. 117). Install stop rings. Center the keys and
balls by pushing on both stop rings.
SHIFT RAILS OVERHAUL
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Fig. 112 Checking Side Gear End Play (Typical)
Fig. 113 Checking Side Gear End Play (Typical)
Fig. 114 Synchronizer Assembly
Fig. 115 Synchronizer Balls
Fig. 116 Synchronizer Sleeve
PLTRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.
TRANSAXLE CASE OVERHAUL
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end±plate cover is
MopartRTV.
The components that are left in the gear cases
when the gear train is pulled out are the:
²Axle shaft seals
²Output bearing race and retainer
²Input bearing and sleeve
²Differential bearing cones
²Shift rail bushings
²Shift shafts
²Shift shaft seals
²Shift shaft bushings
²Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
(1) Insert a flat±blade pry tool at outer edge of
axle shaft seal (Fig. 118).
(2) Tap on the pry tool with a small hammer and
remove axle shaft seal.INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 with C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position (Fig. 119).
OUTPUT BEARING
REMOVAL
NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end±to±end.
Install bearing with larger diameter cage ring facing
out.
Fig. 117 Keys in HubFig. 118 Axle Shaft Seal Removal
Fig. 119 Axle Seal Installation
21 - 30 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro keys and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 136).(3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 137). Be sure drill bit goes into transaxle
case at least one±half inch.
(4) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
Fig. 136 Crossover Cable Adjustment Screw
Fig. 137 Crossover Lever Pin Procedure
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)