DODGE NEON 1999 Service Repair Manual

NOTE: When replacement is required on any com-
ponent of the exhaust system, you must use origi-
nal equipment parts (or their equivalent).
INSTALLATION
When assembling exhaust systemdo nottighten
clamps until components are aligned and clearances
are checked.
(1) Assemble catalytic convertor to exhaust mani-
fold connection. Use a new flange gasket (LEV only)
(Fig. 9) or (Fig. 10).
(2) Assemble exhaust pipe to catalytic convertor
and the support to the underbody
(3) Install the muffler to exhaust pipe and the sup-
ports to the underbody.
(4) Working from the front of system;
(5) Align and tighten the catalytic convertor to
exhaust manifold ball joint bolts to 27 N´m (20 ft.
lbs.) (Fig. 9) or flex-joint attaching nuts (LEV) to 28
N´m (250 in. lbs.).
(6) Align each component to maintain position and
proper clearance with underbody parts (Fig. 11) and
tighten band clamps to specifications (Fig. 12).
CAUTION: Band (Torca) clamps should never be
tighten such that the two sides of the clamps are
bottomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
its clamping force and must be replaced.
(7) Connect the downstream heated oxygen sensor
and lower the vehicle.
INTAKE MANIFOLDÐSOHC ENGINE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the fresh air inlet duct from air
cleaner (Fig. 15).
(4) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 13).
(5) Place the open end of fuel pressure release
hose, Special Tool C-4799-1, into an approved gaso-
line container. Connect the other end of hose to the
fuel pressure test port (Fig. 14). Fuel pressure will
bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1.
(6) Perform fuel system pressure release procedure
before attempting any repairs.
(7) Disconnect the fuel supply line quick connect at
the fuel tube assembly.
Fig. 11 Exhaust Clearance
Fig. 12 Band Clamp (Torca)
Fig. 13 Fuel Pressure Test Port
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
(9) Remove clean air duct and upper air filter
housing (Fig. 15).
(10) Remove accelerator, kickdown and speed con-
trol cables from throttle lever and bracket. Refer to
Group 14, Fuel System Throttle Body Removal for
procedures.
(11) Disconnect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors
(Fig. 16).
(12) Disconnect vacuum hoses from throttle body
(Fig. 16).(13) Disconnect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP), electrical connector
(Fig. 17). Disconnect vapor and brake booster hoses.
(14) Disconnect knock sensor electrical connector
(Fig. 18) and disconnect wiring harness from tab
located on the intake manifold.
(15) Disconnect wiring at starter.
(16) Remove transmission to throttle body support
bracket fasteners at the throttle body and loosen the
fasteners at the transmission end.
(17) Remove throttle body.
(18) Remove EGR tube bolts at the valve and at
the intake manifold (Fig. 19). Remove tube from
engine.
(19) Remove the intake manifold to inlet water
tube support fastener (Fig. 20).
(20) Remove 10 intake manifold screws and wash-
ers. Discard the fasteners. Remove intake manifold.
Fig. 14 Releasing Fuel Pressure
Fig. 15 Clean Air Duct to Throttle Body Assembly
Fig. 16 Idle Air Control (IAC) Motor and Throttle
Position Sensor (TPS) Wiring Connectors and
Vacuum Hose Connection
Fig. 17 Intake Manifold Electrical and Vacuum Hose
Connections
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifold. Clean all mating sur-
faces. Replace all seals, with new seals. All intakemanifold fasteners and washers are to be discarded
andNEWfasteners and washers are to be used.
(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 N´m (105 in. lbs.) in sequence
shown in (Fig. 20).
(2) Install intake manifold to water inlet support.
Tighten fastener (Fig. 20) to 12 N´m (105 in. lbs.).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.). Install transmission to throttle
body support bracket and tighten to 11.9 N´m (105
in. lbs.) at the throttle body first. Next tighten the
bracket at the transmission.
(7) Connect Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) wiring connector.
(8) Connect knock sensor connector, and wiring at
starter. Connect wiring harness to intake manifold
tab.
(9) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(10) Connect vacuum hoses to throttle body.
(11) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(12) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(13) Install clean air duct to air filter housing.
Tighten clamp to 3 N´m (30 in. lbs.).
(14) Connect negative cable to battery.
(15) Install fresh air duct to air cleaner and
tighten wing nut.
(16) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 18 Knock Sensor
Fig. 19 EGR Tube Assembly
Fig. 20 Intake Manifold Tightening Sequence
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INTAKE MANIFOLDÐDOHC ENGINE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Loosen wing nut on intake and remove fresh
air inlet duct (Fig. 23).
(4) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 21).
(5) Place the open end of fuel pressure release
hose, Special Tool C-4799-1, into an approved gaso-
line container. Connect the other end of hose to the
fuel pressure test port (Fig. 22). Fuel pressure will
bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1.
(6) Disconnect the fuel supply line quick-connect at
the fuel tube assembly.
(7) Remove clean air inlet duct.WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(8) Disconnect the coolant temperature sensor
(Fig. 24).
(9) Disconnect heater hose from intake manifold.
(10) Disconnect heater tube from bottom of intake
manifold.
(11) Disconnect upper radiator hose and coolant
recovery hose.
(12) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
Fig. 21 Fuel Pressure Test PortÐTypical
Fig. 22 Releasing Fuel PressureÐTypical
Fig. 23 Fresh Air Inlet Duct
Fig. 24 Engine Coolant Temperature Sensor
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)

(13) Remove accelerator, kickdown and speed con-
trol cables from throttle lever and bracket. Refer to
Group 14, Fuel System Throttle Body Removal for
procedures.
(14) Disconnect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors
(Fig. 25).
(15) Disconnect vacuum hoses from throttle body.
(16) Remove throttle body.
(17) Disconnect Manifold Absolute Pressure/In-
take Air Temperature sensor (TMAP) electrical con-
nector. Disconnect vapor and brake booster hoses
(Fig. 26).(18) Disconnect knock sensor electrical connector
and disconnect wiring harness from tab located on
the heater tube (Fig. 27).
(19) Disconnect wiring from starter.
(20) Remove EGR tube bolts at the valve and at
the intake manifold (Fig. 28). Remove tube from
engine.
(21) Remove intake manifold fasteners. Remove
intake manifolds (upper and lower).
Fig. 25 Idle Air Control (IAC) Motor and Throttle
Position Sensor (TPS) Wiring Connectors
Fig. 26 Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) Electrical Connector
Fig. 27 Knock Sensor Electrical
Fig. 28 EGR Tube Assembly
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.
29) to 28 N´m (250 in. lbs.).
(2) Install intake manifold onto cylinder head and
tighten fasteners to 28 N´m (250 in. lbs.) in sequence
shown in (Fig. 30).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect heater tube and hose to intake mani-
fold.
(7) Connect upper radiator hose and coolant recov-
ery hose.
(8) Connect coolant temperature sensor wiring con-
nector.
(9) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.).
(10) Connect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP) wiring connector.(11) Connect knock sensor connector and starter
wires. Connect wiring harness to heater tube tab.
(12) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(13) Connect vacuum hoses to throttle body.
(14) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(15) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(16) Install fresh air duct to air filter housing.
Tighten clamp to 3 N´m (25 in. lbs.).
(17) Connect negative cable to battery.
(18) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Remove air cleaner assembly and bracket.
(2) Remove exhaust manifold heat shield (Fig. 31).
(3) Disconnect upstream heated oxygen sensor con-
nector.
Fig. 29 Lower Intake Manifold to Upper Tightening
Sequence
Fig. 30 Intake Manifold To Cylinder Head Tightening
Sequence
Fig. 31 Exhaust Manifold Heat Shield
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

(4) Remove exhaust pipe from manifold. Discard
manifold to flex joint gasket, if LEV equipped.
(5) Remove (8) exhaust manifold retaining fasten-
ers and remove exhaust manifold and gasket (Fig.
32).
INSTALLATION
NOTE: Discard gasket and clean all gasket sur-
faces of manifolds and cylinder head.
(1) Position exhaust manifold and gasket in place.
Apply MopartStud and Bearing Mount to fasteners
and tighten to 23 N´m (200 in. lbs.) starting at center
and progressing outward in both directions. Repeat
this procedure until all fasteners are at specified
torque.
(2) Install exhaust manifold heat shield.
(3) Connect upstream heated oxygen sensor con-
nector.
(4) Install air cleaner bracket and assembly.
(5) Replace manifold to flex joint gasket, if LEV
equipped.
(6) Attach exhaust pipe and tighten fasteners to 28
N´m (250 in. lbs.).
CLEANING AND INSPECTION
INTAKE MANIFOLD SOHC
INSPECT AND CLEAN
Check for:
²Inspect manifold for cracks or distortions.
²Check for torn or missing O-rings at the mating
surface of the manifold (Fig. 33).
INTAKE MANIFOLD DOHC
INSPECT AND CLEAN
Check for:
²Inspect manifold for cracks or distortions.²Check for torn gasket at the mating surface of
the manifold.
EXHAUST MANIFOLD
CLEAN AND INSPECT
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head.
(2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion.
Replace manifold if necessary.
SPECIFICATIONS
TORQUE CHART
EGR Tube Attaching
Bolts.....................11N´m(95in.lbs.)
Exhaust Manifold to Exhaust Pipe
Nuts.....................27N´m(20ft.lbs.)
Exhaust Manifold Flange (LEV)
Nuts....................28N´m(250 in. lbs.)
Exhaust Manifold Mounting
Bolts....................23N´m(200 in. lbs.)
Intake Manifold MountingÐSOHC
Bolts....................12N´m(105 in. lbs.)
Intake Manifolds Upper and LowerÐDOHC
Bolts....................28N´m(250 in. lbs.)
Heat Shield Mounting (Body)
Bolts......................4N´m(35in.lbs.)
Exhaust System Band Clamps (Torca)
Fastener..................75N´m(55ft.lbs.)
Exhaust Manifold Heat Shield
Bolts....................23N´m(200 in. lbs.)
Fig. 32 Exhaust Manifold
Fig. 33 Intake Manifold O-Rings
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
GENERAL INFORMATION
EXHAUST SYSTEMS.................... 1
GENERAL INFORMATION
EXHAUST SYSTEMS
The exhaust system for a vehicle that uses leaded
fuel has a resonator, heat shield(s), tailpipe and muf-
fler (Fig. 1).
Fig. 1 Exhaust System Ð Leaded Fuel Vehicles
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

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