fuel DODGE NEON 1999 Service Repair Manual
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Page 3 of 1200
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
²SAE 30 = single grade engine oil.
²SAE 10W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use engine oils that are API Service Certified.
5W-30 and 10W-30 MOPAR engine oils conform to
specifications.
Refer to Group 9, Engine for engine oil specifica-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letterªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
FLUID CAPACITIES
FUEL TANK
All ..........................47.3 L (12.5 gal.)
ENGINE OIL W/FILTER CHANGE
All...........................4.25 L (4.5 qts.)
ENGINE OIL W/OUT FILTER CHANGE
All............................3.8 L (4.0 qts.)
COOLING SYSTEM
All*.............................6L(6.5 qts.)
*Includes heater and coolant recovery bottle
AUTOMATIC TRANSAXLE
NOTE: Overhaul Fill Capacity with Torque Con-
verter Empty
31TH .........................8.4 L (8.9 qts.)
31 TH (Fleet Vehicles).............8.7 L (9.2 qts.)
MANUAL TRANSAXLE
NV T350.................1.9-2.2 L (4.0-4.6 pts.)
POWER STEERING
All...........................0.95 L (2.0 pts.)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCEPL
GENERAL INFORMATION (Continued)
Page 4 of 1200
MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to. Use the schedule that best
describes these conditions.
Schedule ±A, lists maintenance recommended for
vehicles used for general transportation.
Schedule ±B, lists maintenance recommended for
vehicles used under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Frequent trailer towing
²Extensive idling
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)
Where time and mileage are listed, follow the
interval that occurs first.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery, clean, and tighten terminals as
required.
²Check fluid levels of coolant reservoir, power
steering and automatic transmission and add as
required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on schedule ± B (6,000 miles).
²Check coolant level, hoses and clamps.
²Check the manual transaxle fluid level.
²If the mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
²Adjust drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Replace engine oil filter.
²Lubricate front suspension ball joints.
²Adjust drive belt tension.
PLLUBRICATION AND MAINTENANCE 0 - 3
Page 8 of 1200
JUMP STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS............ 9JUMP STARTING PROCEDURE.............. 7
TOWING RECOMMENDATIONS.............. 8
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, placethe automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
PLLUBRICATION AND MAINTENANCE 0 - 7
Page 9 of 1200
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)
Page 16 of 1200
PRE-ALIGNMENT VEHICLE INSPECTION
CAUTION: If the front suspension crossmember
shows any sign of impact damage, the steering col-
umn to steering gear coupling must be inspected.
Refer to Group 19 Steering in this service manual
for the inspection procedure.
Before any attempt is made to change or correct
the wheel alignment factors, the following inspection
and necessary corrections must be made on those
parts which influence the steering of the vehicle.
(1) Be sure the fuel tank is full when the wheel
alignment specifications are checked and or adjusted.
A full tank of fuel weighs approximately 75 pounds,
if the fuel tank is not full this reduction in weight
will affect the curb height of the vehicle and the
alignment specifications.
(2) Alignment specifications of a vehicle can be the
most accurately checked and set when the passenger
compartment and trunk of the vehicle are vacant
with the exception of the spare tire. People, luggage,
and any other appreciable weight will adversely
affect the checking and setting of the camber specifi-
cation.
(3) Check and if required, inflate all of the tires to
the recommended air pressure. All tires must be of
the same size and in good condition and have approx-
imately the same tread wear.Note the type of
tread wear on the tire, this will aid in diagnos-
ing problems. Refer to Group 22 Tires And
Wheels in this service manual for the tire wear
diagnosis.
(4) Check the front tire and wheel assemblies for
radial runout.
(5) Before beginning the alignment process,
inspect all suspension component fasteners for loose-
ness and/or loss of specified torque.
(6) Inspect the lower front ball joints and all steer-
ing linkage for looseness and any signs of wear and
or damage.
(7) Inspect the tie rod ends for looseness and any
signs of wear and or damage.
(8) Inspect the rubber bushings on all suspension
components for signs of wear or deterioration. If any
bushings show signs of wear or deterioration they
should be replaced prior to aligning the vehicle.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER CAMBER
Front and rear Caster and Camber settings on this
vehicle are determined at the time the vehicle isdesigned, by the location of the vehicle's suspension
components. This is called a Net Build vehicle and
results in no required adjustment of Caster and
Camber after vehicle is built or when servicing the
suspension components. Thus Caster and Camber are
not normally considered an adjustable specification
when performing an alignment on this vehicle.
Though Caster and Camber are not adjustable they
must be checked to ensure they meet vehicle specifi-
cations.
If front and or rear camber is found not to meet
the vehicle alignment specifications, it can be
adjusted using a Mopar Service Kit developed to
allow for camber adjustment. If a vehicle's front or
rear camber is found to be outside the specifications,
the vehicles suspension components should be
inspected for any signs of damage on bending.This
must be done before using the Mopar Service
Kit for setting camber to meet required specifi-
cation.
If a vehicles caster is not within manufacturers
alignment specifications, check for damaged suspen-
sion components or body parts. This type of damage
can cause component locations to move affecting
vehicle alignment.No adjustment can be made
for the Caster setting on this vehicle.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or any other
modification of the suspension components.
(1) Correctly position vehicle on alignment rack
and install all required equipment on vehicle, per the
alignment equipment manufacturers specifications.
(2) Center the steering wheel and lock in place
using a steering wheel clamp.
NOTE: Prior to reading each alignment specifica-
tion, jounce the front and rear of the vehicle an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Correctly jounce vehicle and read front and
rear alignment settings and compare to vehicle spec-
ifications for Camber, Caster and Toe. See Alignment
Specifications in this group of the service manual for
required specifications.If front and rear camber
readings are within required specifications pro-
ceed to step Step 3 in the Front And Rear Toe
Setting procedure. If Camber readings are not
within specifications refer to step Step 1 in the
following camber adjustment bolt package
installation procedure, for the front and rear
Camber adjustment procedure.
PLSUSPENSION 2 - 5
DIAGNOSIS AND TESTING (Continued)
Page 201 of 1200
COOLING SYSTEM DIAGNOSIS CONT.
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM.7. Coolant level low in radiator but
not in coolant overflow/reserve
tank. This means the radiator is not
drawing coolant from the coolant
overflow/reserve tank as the engine
cools.
As the engine cools, a vacuum is
formed inside the cooling system. If
the radiator cap seals are defective,
or the cooling system has a leak, a
vacuum can not be formed.7. (a) Check condition of radiator
cap and cap seals. Replace cap if
necessary.
(b) Check condition of filler neck. If
neck is damaged, replace filler
neck.
(c) Check condition of hoses from
filler neck to coolant tank. It should
be tight at both ends without any
kinks or tears. Replace hose if
necessary.
(d) Check coolant overflow/reserve
tank and tank hoses for blockage.
Repair as necessary.
8. Freeze point of coolant not
correct. Mixture may be to rich.8. Check coolant. Refer to coolant
section in this group. Adjust glycol
to water ratio as required.
9. Coolant not flowing through
system.9. Check for coolant flow at filler
neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through filler neck. If flow is not
observed determine reason for lack
of flow and repair as necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.10. Clean insects or debris.
11. Radiator core is plugged or
corroded.11. Replace or re-core radiator.
12. Fuel or ignition system
problems.12. Refer to Fuel and Ignition
System group for diagnosis. Also
refer to the appropriate Powertrain
Diagnosis Procedures manual for
operation of the DRB scan tool.
13. Dragging brakes. 13. Inspect brake system and repair
as necessary. Refer to Group 5,
Brakes for diagnosis.
14. Bug screen is being used
causing reduced air flow.14. Remove bug screen.
15. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.15. Check thermostat operation and
replace as necessary. Refer to
thermostats in this group.
16. Electric cooling fan not
operating properly.16. Check electric fan operation and
repair as necessary.
17. Cylinder head gasket leaking. 17. Check cylinder head gasket for
leaks. Refer to testing cooling
system for leaks. For repairs, refer
to group 9, Engines.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.
7 - 8 COOLINGPL
DIAGNOSIS AND TESTING (Continued)
Page 207 of 1200
WATER PUMP DIAGNOSIS
A quick flow test to tell whether or not the pump is
working is to see if the heater warms properly. A
defective pump will not be able to circulate heated
coolant through the long heater hose.
Another flow test to help determine pump opera-
tion.
WARNING: DO NOT remove radiator cap if the cool-
ing system is hot or under pressure.
(1) Remove radiator cap.
(2) Remove a small amount of coolant from the
system, start the engine and warm up until thermo-
stat opens. With the thermostat open and coolant
level low you will see if the water pump is pumping
coolant through the system.
COOLING SYSTEM FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use the following procedures:
(1) If engine is cold, idle engine until normal oper-
ating temperature is reached. Then feel the upper
radiator hose. If it is hot, coolant is circulating.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
(2) Remove pressure cap when engine is cold,
remove small amount of coolant Idle engine until
thermostat opens, you should observe coolant flow
while looking down the filler neck. Once flow is
detected install the pressure cap.
RADIATOR FAN CONTROL
Fan control is accomplished two ways. The fan
always runs when the air conditioning compressor
clutch is engaged. In addition to this control, the fan
is turned on by the temperature of the coolant which
is sensed by the coolant temperature sensor which
sends the message to the Powertrain Control Module
(PCM). The (PCM) turns on the fan through the
Solid State Fan Relay. The Solid State Fan Relay is
located on the left front inner frame just behind the
radiator. See Wiring Diagrams Manual for circuity
and diagnostics provided.
Switching through the (PCM) provides fan control
for the following conditions.
²The fan will not run during cranking until the
engine starts no matter what the coolant tempera-
ture is.
²Fan will run when the air conditioning clutch is
engaged and low pressure cutout switch is closed.
²Fan will run at vehicle speeds above about 40
mph only if coolant temperature reaches 110ÉC(230ÉF). It will turn off when the temperature drops
to 104ÉC (220ÉF). At speeds below 40 mph the fan
switches on at 102ÉC (215ÉF) and off at 93ÉC (200ÉF).
Refer to Radiator Fan Control Module Group 14,
Fuel Injection for more information.
ELECTRIC FAN MOTOR TEST
Refer to Powertrain Diagnostic Manual for procedure.
TESTING COOLING SYSTEM FOR LEAKS
The system should be full. With the engine not
running, wipe the filler neck sealing seat clean.
Attach a radiator pressure tester to the filler neck,
as shown in (Fig. 9) and apply 104 kPa (15 psi) pres-
sure. If the pressure drops more than 2 psi in 2 min-
utes, inspect the system for external leaks.
Move all hoses at the radiator and heater while
system is pressurize at 15 psi, since some leaks occur
due to engine rock while driving.
If there are no external leaks after the gauge dial
shows a drop in pressure, detach the tester. Start the
engine, and run the engine to normal operating tem-
perature in order to open the thermostat and allow
the coolant to expand. Reattach the tester. If the nee-
dle on the dial fluctuates it indicates a combustion
leak, usually a head gasket leak.
WARNING: WITH THE PRESSURE TESTER IN
PLACE PRESSURE BUILDS UP QUICKLY. ANY
EXCESSIVE PRESSURE BUILD-UP DUE TO CON-
TINUOUS ENGINE OPERATION MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
coolant or steam is emitted from the tail pipe, it may
indicate a faulty head gasket, cracked engine block,
or cracked cylinder head.
Fig. 9 Pressure Testing Cooling SystemÐTypical
7 - 14 COOLINGPL
DIAGNOSIS AND TESTING (Continued)
Page 220 of 1200
NOTE: BLACK OR DARK=0to75%state-of-charge
The battery is INADEQUATELY charged and must
be charged until green dot is visible, (12.4 volts or
greater) before the battery is tested or returned to
use. Refer to Causes of Battery Discharging in this
Group for more information.
NOTE: CLEAR COLOR = Replace Battery
WARNING: DO NOT CHARGE, ASSIST BOOST,
LOAD TEST, OR ADD WATER TO THE BATTERY
WHEN CLEAR COLOR DOT IS VISIBLE. PERSONAL
INJURY MAY OCCUR.
A clear color dot shows electrolyte level in battery
is below the test indicator (Fig. 1). Water cannot be
added to a maintenance free battery. The battery
must be replaced. A low electrolyte level may be
caused by an over charging condition. Refer to Gen-
erator Test Procedures on Vehicle.
CAUSES OF BATTERY DISCHARGING
It is normal to have a small 5 to 25 milliamperes
continuous electrical draw from the battery. This
draw will take place with the ignition in the OFF
position, and the courtesy, dome, storage compart-
ments, and engine compartment lights OFF. The con-
tinuous draw is due to various electronic features or
accessories that require electrical current with the
ignition OFF to function properly. When a vehicle is
not used over an extended period of approximately 20
days the IOD fuse should be pulled. The fuse is
located in the power distribution center. removal of
this fuse will reduce the level of battery discharge.
Refer to the Battery Diagnosis and Testing Table for
proper diagnosis.
ABNORMAL BATTERY DISCHARGING
²Corroded battery posts, cables or terminals.
²Loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system due to equipment or accessories
installed after delivery.
²Slow driving speeds in heavy traffic conditions
or prolonged idling with high-amperage electrical
systems in use.
²Defective electrical circuit or component causing
excess Ignition Off Draw (IOD). Refer to Battery
Ignition Off Draw (IOD).
²Defective charging system.
²Defective battery.
BATTERY IGNITION OFF DRAW (IOD)
High current draw on the battery with the ignition
OFF will discharge a battery. After a dead battery is
recharged, the vehicle ignition off draw (IOD) shouldbe checked. To determine if a high current draw con-
dition exists first check the vehicle with a test lamp.
(1) Verify that all electrical accessories are OFF.
²Remove key from ignition switch
²Turn off all lights
²Trunk lid is closed
²Engine compartment hood lamp is disconnected
or lamp removed
²Glove box door is closed
²Sun visor vanity lights are OFF
²All doors are closed
²Allow the ignition key lamp system to time out
in approximately 30 seconds, if equipped.
(2) Disconnect battery negative cable (Fig. 4).
(3) Connect a 12 Volt test lamp, with a cold resis-
tance of 5-7 ohms, between the battery negative cable
clamp and the negative post (Fig. 5). If test lamp
goes out system is OK. If test lamp lights and stays
ON, go to Test Lamp Stays ON procedure.
TEST LAMP STAYS ON
There is either a short circuit or a fault in an elec-
tronic module. Two fuses in the Power Distribution
Center (PDC) feed the modules with ignition off
draw.
²Interior lamps fuse (10 Amp) (IOD) PDC.
²Fuel pump fuse (20 Amp) in PDC
(1) Remove interior lamp and fuel pump fuses. By
removing these fuses all ignition off draw from the
vehicle electronics will be disconnected. The test
lamp should go out. If test lamp goes out go to Step
2. If test lamp does not go out there is a current
draw or short circuit. Refer to Group 8W, Wiring Dia-
grams.
(2) Install the fuel pump fuse. If test lamp lights,
there is a current draw or short circuit in the A14
wiring circuit feed.
(a) Disconnect Powertrain Control Module.
(b) If test lamp goes out, replace Powertrain
Control Module.
(c) If test lamp does not go out, there is a cur-
rent draw or short circuit in the A14 circuit feed.
Refer to Group 8W, Wiring Diagrams.
(3) Install the interior lamp fuse. If test lamp
lights, there is a current draw or short circuit in the
M01 circuit. Refer to Group 8W, Wiring Diagrams. If
test lamp stays out, go to Step 4
(4) Use a multi-meter that has at least a range of
200 milliamperes. Install meter between the battery
negative cable and battery negative post (Fig. 6).
Carefully remove the test lamp without disconnecting
the meter. After all modules time-out the total vehi-
cle IOD should be less than 10 milliamperes. If igni-
tion off draw is more than 10 milliamperes go to Step
5.
(5) Remove both fuses from the Power Distribution
Center:
PLBATTERY 8A - 3
DIAGNOSIS AND TESTING (Continued)
Page 221 of 1200
²Fuel pump fuse (20 Amp)
²Interior lamps fuse (10 Amp)
(6) If there is any reading with fuses removed
there is a current draw or short circuit in the wiring.
Refer to Group 8W, Wiring Diagrams. If OK go to
Step 7.
(7) Install interior lamp fuse. After installing fuse,
the current can reach 250 milliamperes. After time-out the reading should not exceed 8 milliamperes. If
NOT OK go to Step 8. If OK go to Step 9.
²Ignition key lamp system
²Radio
²Remote keyless entry module, if equipped
(8) Disconnect radio and ignition switch key lamp
one component at time, to see if any component is at
fault. If the high reading is not eliminated there is a
short circuit in the wiring. Refer to Group 8W, Wir-
ing Diagrams.
CAUTION: Always disconnect the meter before
opening a door.
(9) Remove interior lamps fuse and install the fuel
pump fuse. The reading should be between 1-3 milli-
amperes. If reading is higher than 3 milliamperes:
(a) Disconnect Powertrain Control Module.
(b) If reading drops to zero, replace Powertrain
Control Module.
(c) If reading remains the same there is a cur-
rent draw or short circuit in the A14 circuit. Refer
to Group 8W, Wiring Diagrams.
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.(1) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(2) Battery OK.(1) Replace Battery
(2) Check state of charge. Refer to
Test Indicator.
TEST INDICATOR
Check Charge Eye Color(1) GREEN
(2) BLACK
(3) CLEAR(1) Battery is charged. Perform
Battery 0pen Circuit Voltage Test
(2) Perform Battery Charging
procedure.
(3) Replace Battery.
BATTERY OPEN CIRCUIT
VOLTAGE TEST(1) Battery is above 12.40 Volts
(2) Battery is below 12.40 Volts.(1) Perform the Battery Load Test.
(2) Perform Battery Charging
procedure.
BATTERY CHARGING (1) Battery accepted Charge.
(2) Battery will not accept charge(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test
(2) Perform Charging a Completely
Discharged Battery.
BATTERY LOAD TEST (1) Acceptable minimum voltage.
(2) Unacceptable minimum voltage(1) Battery is OK to put in use,
perform Battery Ignition Off Draw
Test.
(2) Replace Battery and perform
Battery Ignition Off Draw Test.
CHARGING A COMPLETELY
DISCHARGED BATTERY(1) Battery accepted charge.
(2) Battery will not accept charge.(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test.
(2) Replace Battery.
IGNITION OFF DRAW TEST (1) IOD is 5-25 Milliamperes.
(2) IOD Exceeds 25 Milliamperes.(1) Vehicle is normal.
(2) Eliminate excess IOD draw.
Fig. 4 Disconnect Battery Negative Cable
8A - 4 BATTERYPL
DIAGNOSIS AND TESTING (Continued)
Page 228 of 1200
STARTING
CONTENTS
page page
GENERAL INFORMATION
BOSCH STARTER........................ 1
INTRODUCTION......................... 1
SUPPLY CIRCUIT AND CONTROL CIRCUIT.... 1
DIAGNOSIS AND TESTING
FEED CIRCUIT RESISTANCE TEST........... 2
FEED CIRCUIT TEST...................... 2
STARTER CONTROL CIRCUIT.............. 1STARTING SYSTEM TEST................. 4
REMOVAL AND INSTALLATION
SAFETY SWITCHES...................... 6
STARTER RELAY........................ 7
STARTER .............................. 6
SPECIFICATIONS
STARTER .............................. 7
TORQUE............................... 7
GENERAL INFORMATION
INTRODUCTION
The starting system (Fig. 1) has:
²Ignition switch
²Starter relay
²Neutral starting and back up switch
²Clutch pedal position switch
²Wiring harness
²Battery
²Starter motor with an integral solenoid
BOSCH STARTER
The Bosch is a permanent magnet starter motor. A
planetary gear train transmits power between starter
motor and pinion shaft. The fields have six perma-
nent magnets. The starter system consists of two
separate circuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate cir-
cuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
DIAGNOSIS AND TESTING
STARTER CONTROL CIRCUIT
The starter control circuit has:
²Starter solenoid
²Starter relay²Neutral starting and back up switch with auto-
matic transmissions
²Clutch pedal position switch with manual trans-
mission
²Ignition switch
²Battery
²All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 1 Starting System
PLSTARTING 8B - 1