Fuel line DODGE NEON 1999 Service Repair Manual

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR
TOW VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust
system, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do not
secure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing overrough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²5-speed manual transaxle vehicles can be flat
towed at any legal highway speed for extended dis-
tances. The gear selector must be in the neutral posi-
tion.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²Verify that front drive line and steering compo-
nents are in good condition.
²5-speed manual transaxle vehicles can be towed
at any legal highway speed for extended distances.
The gear selector must be in the neutral position.
²3-speed automatic transaxle vehicles can be
towed at speeds not to exceed 40 km/h (25 mph) for
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCEPL
SERVICE PROCEDURES (Continued)

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.
SPARK PLUG CONDITION
NORMAL OPERATING CONDITIONS
The few deposits present will be probably light tan
or slightly gray in color with most grades of commer-
cial gasoline (Fig. 21). There will not be evidence of
electrode burning. Gap growth will not average more
than approximately 0.025 mm (.001 in) per 1600 km
(1000 miles) of operation for non platinum spark
plugs. Non-platnium spark plugs that have normal
wear can usually be cleaned, have the electrodes filed
and regapped, and then reinstalled.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum spark plugs.
This would damage the platinum pads which would
shorten spark plug life.Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
may coat the entire tip of the spark plug with a rust
colored deposit. The rust color deposits can be misdi-
agnosed as being caused by coolant in the combustion
chamber. Spark plug performance is not affected by
MMT deposits.
COLD FOULING (CARBON FOULING)
Cold fouling is sometimes referred to as carbon
fouling because the deposits that cause cold fouling
are basically carbon (Fig. 21). A dry, black deposit on
one or two plugs in a set may be caused by sticking
valves or misfire conditions. Cold (carbon) fouling of
the entire set may be caused by a clogged air cleaner.
Cold fouling is normal after short operating peri-
ods. The spark plugs do not reach a high enough
operating temperature during short operating peri-
ods.Replace carbon fouled plugs with new
spark plugs.
FUEL FOULING
A spark plug that is coated with excessive wet fuel
is called fuel fouled. This condition is normally
observed during hard start periods.Clean fuel
fouled spark plugs with compressed air and
reinstall them in the engine.
OIL FOULING
A spark plug that is coated with excessive wet oil
is oil fouled. In older engines, wet fouling can be
caused by worn rings or excessive cylinder wear.
Break-in fouling of new engines may occur before
normal oil control is achieved.Replace oil fouled
spark plugs with new ones.
OIL OR ASH ENCRUSTED
If one or more plugs are oil or ash encrusted, eval-
uate the engine for the cause of oil entering the com-
bustion chambers (Fig. 22). Sometimes fuel additives
can cause ash encrustation on an entire set of spark
plugs.Ash encrusted spark plugs can be cleaned
and reused.
HIGH SPEED MISS
When replacing spark plugs because of a high
speed miss condition;wide open throttle opera-
tion should be avoided for approximately 80 km
(50 miles) after installation of new plugs.This
will allow deposit shifting in the combustion chamber
to take place gradually and avoid plug destroying
splash fouling shortly after the plug change.
Fig. 21 Normal Operation and Cold (Carbon) Fouling
8D - 10 IGNITION SYSTEMPL
DIAGNOSIS AND TESTING (Continued)

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
DOME LAMP............................ 1
ELECTRONIC DIGITAL CLOCK.............. 1
INSTRUMENT CLUSTER................... 2
WARNING AND INDICATOR LAMPS......... 2
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM............... 2
BRAKE SYSTEM WARNING LAMP TEST...... 2
FOG LAMP SWITCH TEST................. 2
FUEL TANK SENDING UNIT TEST........... 3
HEADLAMP SWITCH TEST................. 3
HEATER A/C BLOWER SWITCH TEST........ 3
HEATER BLOWER SWITCH TEST............ 3
INDIVIDUAL GAUGE INOPERATIVE.......... 4
INSTRUMENT PANEL AND COMPONENTS.... 4
LOW OIL PRESSURE WARNING LAMP TEST . . 4
MULTIPLE GAUGE INOPERATIVE TEST....... 4
SEAT BELT REMINDER SYSTEM TEST....... 6
SENDING UNIT......................... 6
SERVICE ENGINE SOON INDICATOR......... 6
VEHICLE SPEED SENSOR TEST............. 6
REMOVAL AND INSTALLATION
ASH RECEIVER RETAINER AND LAMP....... 6
CENTER BEZEL.......................... 6
CIGAR LIGHTER RECEPTACLE.............. 6
CLUSTER LAMP......................... 7
CLUSTER PRINTED CIRCUIT BOARD........ 7CLUSTER.............................. 7
DOME LENS/LAMP....................... 8
FLOOR CONSOLE........................ 8
GAUGE................................ 8
GLOVE BOX DOOR/BIN................... 8
GLOVE BOX SWITCH/LAMP................ 9
HEADLAMP SWITCH..................... 9
HEATER A/C CONTROL BLOWER SWITCH . . . 10
HEATER A/C CONTROL LAMP............ 10
HEATER A/C CONTROL................... 9
HEATER CONTROL BLOWER SWITCH....... 10
IGNITION KEY LAMP.................... 10
INSTRUMENT PANEL.................... 10
LEFT TRIM PANEL...................... 10
ODOMETER............................ 10
RADIO................................ 12
REAR WINDOW DEFOGGER AND/OR FOG
LAMP SWITCH....................... 12
RIGHT TRIM PANEL..................... 12
SHIFTER KNOB......................... 13
STEERING COLUMN COVER LINER......... 13
STEERING COLUMN COVER.............. 13
STEERING COLUMN SHROUDS............ 13
TOP COVER AND CLUSTER BEZEL
REMOVAL........................... 14
TRANSMISSION RANGE INDICATOR LAMP . . 14
TRUNK LAMP/LENS..................... 14
VEHICLE SPEED SENSOR................ 14
GENERAL INFORMATION
INTRODUCTION
The purpose of the dash gauges and indicator
lamps is to keep the driver informed about the oper-
ating condition of the vehicle. If an abnormal condi-
tion occurs, the driver is informed by indicator lamp.
The driver can seek service before damage occurs.
Indicator lamps use ON/OFF switch functions for
operation, while gauges use a sending unit or sensor.
DESCRIPTION AND OPERATION
DOME LAMP
The Dome Lamp operates when a door is open or
when the headlamp switch is placed in courtesy posi-
tion.
ELECTRONIC DIGITAL CLOCK
The electronic digital clock is in the radio. The
clock and radio each use the display panel built into
the radio. A digital readout indicates the time in
hours and minutes whenever the ignition switch is in
the ON or ACC position.
PLINSTRUMENT PANEL AND SYSTEMS 8E - 1

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 4
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 4ADJUSTMENTS
FOG LAMP ALIGNMENT................... 4
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN.............................. 4
GENERAL INFORMATION
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method
provided in this section.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 1).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen from 178 mm (7 in.) below the headlamp cen-
ter line. The side- to-side left edge of low beam hot
spot should be 127 mm (5 in.) to the right of head-
lamp center line (Fig. 1). The high beams on a vehi-
cle with aero headlamps cannot be aligned. The high
beam pattern should be correct when the low beams
are aligned properly.
To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern.
FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to Alignment
Screen Preparation paragraph in this section. Disen-
gage the wire connectors from the back of the head-
lamp bulbs to disable the headlamps. This will allow
a more accurate projection reading of the fog lamps.
Turn on the headlamp switch and actuate the fog
lamp switch. A properly aligned fog lamp will project
a pattern on the alignment screen 100 mm (4 in.)
below the fog lamp centerline and straight ahead
(Fig. 2).
8L - 4 LAMPSPL

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)

(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.)
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
CHECKING ENGINE OIL LEVEL
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Add only when the level is at or below the
ADD mark (Fig. 5).
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 6).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 7).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
Fig. 5 Oil Level
Fig. 6 Temperature/Engine Oil Viscosity
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST........................ 8
CYLINDER COMPRESSION PRESSURE TEST . . 7
ENGINE DIAGNOSISÐMECHANICAL......... 11
ENGINE DIAGNOSISÐPERFORMANCE...... 10GENERAL INFORMATION.................. 7
INSPECTION (ENGINE OIL LEAKS IN
GENERAL)............................ 8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS..... 7
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS.. 8
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System, for the fuel system diag-
nosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If a change in RPM'S, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
(7) Repeat the previous step for all remaining cyl-
inders.
(8) Compression should not be less than (689kPa)
100 psi and not vary more than 25 percent from cyl-
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
PLENGINE 9 - 7

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
9 - 8 ENGINEPL
DIAGNOSIS AND TESTING (Continued)

(3) Remove the power hop damper bracket, if nec-
essary.
(4) Reverse removal procedure for installation.
Tighten all bolts and nuts to 54 N´m (40 ft. lbs.)
STRUCTURAL COLLARÐ2.0L
REMOVAL
(1) Raise vehicle on hoist.
NOTE: To remove transaxle dust cover, the front
bending strut must be removed.
(2) Remove structural collar from oil pan to tran-
saxle (Fig. 14).
INSTALLATION
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(1) Install the structural collar (Fig. 14) using the
following 3 step torque sequence:
²Step 1: Install the collar to oil pan bolts and
tighten to 3 N´m (30 in. lbs.).
²Step 2: Install collar to transaxle bolts and
tighten to 108 N´m (80 ft. lbs.).
²Step 3: Final torque the collar to oil pan bolts to
54 N´m (40 ft. lbs.).
(2) Lower vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect and remove battery and tray. Set
Powertrain Control Module (PCM) aside.
(3) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(4) Remove upper radiator hose, radiator and fan
module. Refer to Group 7, Cooling System for proce-
dure.
(5) Remove lower radiator hose.
(6) Disconnect automatic transmission cooler lines
and plug. If equipped.
(7) Disconnect clutch cable (Manual) and transmis-
sion shift linkage.
Fig. 12 Engine MountingÐRight
Fig. 13 Power Hop Damper
Fig. 14 Structural CollarÐRemoval and Installation
PL2.0L SOHC ENGINE 9 - 19
REMOVAL AND INSTALLATION (Continued)

(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Remove air cleaner inlet duct (Fig. 17)
(2) Remove ignition coil pack (Fig. 18).
(3) Remove the cylinder head cover bolts.
(4) Remove cylinder head cover from cylinder
head.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new cylinder head cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install cover assembly to head and tighten fas-
teners to 12 N´m (105 in. lbs.).
(3) Install ignition coil pack. Tighten fasteners to
23 N´m (200 in. lbs.).
SPARK PLUG TUBE
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 19). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
Fig. 17 Inlet Duct Removal
Fig. 18 Ignition Coil Pack
PL2.0L SOHC ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)