lug pattern DODGE NEON 1999 Service Repair Manual

ply circuit shorts to ground, neither sensor will pro-
duce a signal (output voltage to the PCM).
When the ignition key is turned and left in the On
position, the PCM automatically energizes the Auto
Shutdown (ASD) relay. However, the controller de-en-
ergizes the relay within one second because it has
not received a camshaft position sensor signal indi-
cating engine rotation.
During cranking, the ASD relay will not energize
until the PCM receives a camshaft position sensor
signal. Secondly, the ASD relay remains energized
only if the controller senses a crankshaft position
sensor signal immediately after detecting the cam-
shaft position sensor signal.
(1) Check battery voltage. Voltage should approxi-
mately 12.66 volts or higher to perform failure to
start test.
(2) Disconnect the harness connector from the coil
pack (Fig. 20).
(3) Connect a test light to the B+ (battery voltage)
terminal of the coil electrical connector and ground.
The B+ wire for the DIS coil is the center terminal.
Do not spread the terminal with the test light
probe.
(4) Turn the ignition key to theON position.The
test light should flash On and then Off.Do not turn
the Key to off position, leave it in the On posi-
tion.
(a) If the test light flashes momentarily, the
PCM grounded the ASD relay. Proceed to step 5.
(b) If the test light did not flash, the ASD relay
did not energize. The cause is either the relay or
one of the relay circuits. Use the DRB scan tool to
test the ASD relay and circuits. Refer to the appro-
priate Powertrain Diagnostics Procedure Manual.
Refer to the wiring diagrams section for circuit
information.
(5) Crank the engine. (If the key was placed in the
off position after step 4, place the key in the On posi-tion before cranking. Wait for the test light to flash
once, then crank the engine.)
(6) If the test light momentarily flashes during
cranking, the PCM is not receiving a crankshaft posi-
tion sensor signal.
(7) If the test light did not flash during cranking,
unplug the crankshaft position sensor connector.
Turn the ignition key to the off position. Turn the
key to the On position, wait for the test light to
momentarily flash once, then crank the engine. If the
test light momentarily flashes, the crankshaft posi-
tion sensor is shorted and must be replaced. If the
light did not flash, the cause of the no-start is in
either the crankshaft position sensor/camshaft posi-
tion sensor 8 volt supply circuit, or the camshaft
position sensor output or ground circuits.
IGNITION TIMING PROCEDURE
The engines for this vehicle, use a fixed ignition
system. The PCM regulates ignition timing. Basic
ignition timing is not adjustable.
CAMSHAFT POSITION SENSOR AND CRANKSHAFT
POSITION SENSOR
The output voltage of a properly operating cam-
shaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By
connecting an Moper Diagonostic System (MDS) and
engine analyzer to the vehicle, technicians can view
the square wave pattern.
ENGINE COOLANT TEMPERATURE SENSOR
Refer to Group 14, Fuel System for Diagnosis and
Testing.
INTAKE AIR TEMPERATURE SENSOR
Refer to Group 14, Fuel System, for Diagnosis and
Testing.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST
Refer to Group 14, Fuel System for Diagnosis and
Testing.
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.
Fig. 20 Ignition Coil Engine Harness Connector
PLIGNITION SYSTEM 8D - 9
DIAGNOSIS AND TESTING (Continued)

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

(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
(6) Disconnect the fresh air hose (makeup air) at
the cylinder head cover and plug or cap the nipple on
the cover.
(7) Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) Clean the oil off the suspect oil leak area
using a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. Thefollowing steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil galley cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified. Refer to Rear
Crankshaft Seals, for proper replacement procedures.
PLENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)

DESCRIPTION AND OPERATION
SHIFT LEVERS
The shift levers are serviceable in the vehicle. The
shift levers are different from each other and do not
interchange.
SELECTOR LEVER
The selector shaft uses a lever with a weight on
the end. The weight is used to improve shift feel and
reduce noise.
The selector lever is retained by two roll pins (one
inside the other).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings, or
gear teeth may be worn or damaged.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
All NV T350 (A-578) transaxles are equipped with
a fill plug. The fill plug is located on the left side of
the transaxle differential area (Fig. 3). The fluid level
should be within 3/16 inch from the bottom of the
transaxle fill hole (vehicle must be level when check-
ing).
All NV T350 (A-578) transaxles are equipped with
a drain plug. The drain plug is located on the lower
right side of the transaxle differential housing (Fig.
4). Tighten drain plug to 28 N´m (250 in. lbs.)
Dry fill lubricant capacity is approximately 1.9-2.2
liters (4.0-4.6 pints). Wipe the outside of the tran-
saxle if any lubricant spills.
Fig. 2 NV T350 (A-578) Shift Pattern
PLTRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)