key DODGE NEON 2000 Service Owners Manual

CAV CIRCUIT FUNCTION
1
Z1 18BK GROUND
2
L7 18BK/YL HEADLAMP SWITCH OUTPUT
3 L62 18BR/RD RIGHT TURN SIGNAL
RIGHT TAIL/STOP/
TURN SIGNAL LAMP
SEAT BELT SWITCH
1 2
BLACK
SEAT BELT SWITCH SENSE 20LG/RD G10 1
GROUND 18BK Z1 2
FUNCTION CIRCUIT CAV
(EXCEPT BUILT-UP-EXPORT)
M1 20PKFUSED B(+) GROUND
Z1 18BK X5 20WT/RDDISPLAY BACKLIGHT
4
1
SIREN
DISPLAY BACKLIGHT
X5 20WT/RDFUNCTION
CAV CIRCUIT
1
2
4 3
MODULE IMMOBILIZER
- -- -
FUSED B(+)
M1 20PKGROUND
Z2 20BK/LGFUSED IGNITION SWITCH OUTPUT (ST-RUN)
G5 20DB/WTPCI BUS D25 22VT/YL1
6
SENTRY KEY
FUNCTION
CAV CIRCUIT
1
2
4 3
6 5
RIGHT TAIL/STOP
LAMP
(BUILT-UP-EXPORT)
1 3
HEADLAMP SWITCH OUTPUTGROUND Z1 18BK
3
CAV CIRCUIT FUNCTION
1
L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK/YL
(BUILT-UP-EXPORT)
31
BLACK
BLACK
BLACK
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
PLI08045008W-10

Z1 20BK
2 CAV
1CIRCUIT
GROUNDFUNCTION
M1 20PK FUSED B(+)
UNDERHOOD
LAMP
CONTROL SERVOVEHICLE SPEED
41BLACK
GROUND 20BK Z1 4SPEED CONTROL BRAKE LAMP SWITCH OUTPUT 20DB/RD V30 3
SPEED CONTROL VENT SOLENOID CONTROL 20LG/RD V35 2
SPEED CONTROL VACUUM SOLENOID CONTROL 20TN/RD V36 1
FUNCTION CIRCUIT CAV
21
3 Z1 20BK GROUND
4 E2 22OR PANEL LAMPS DRIVER 4
1
SWITCH TRACTION CONTROL
TRACTION CONTROL SWITCH SENSE B27 20RD/YL 2- 1
FUNCTION CIRCUIT CAV
-
2
1
DECKLID SECURITY SWITCH SENSE G71 20VT/YL
GROUND
Z1 18BKFUNCTION
CAV CIRCUIT
1
2
CAV CIRCUIT FUNCTION
1- -
2 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
3 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
BLACK
1
23
TORQUE CONVERTER
CLUTCH SOLENOID
(ATX)
TRUNK KEY
CYLINDER SWITCH
BLACK
GRAY
WHITE
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47
PLI08047008W-10

Connector
Name/NumberColor Location Fig.
Proportional
EVAP/Purge
SolenoidBK Left Rear of
Engine
Compartment2
Radiator Fan
MotorBK Front of
Engine
Compartment2
Radio - C1 BK Rear of Radio 7
Radio - C2 GY Rear of Radio 7
Rear Window
Defogger
SwitchBK Center of
Instrument
Panel7
Remote
Keyless Entry
ModuleBK Center of
Instrument
Panel7
Right Back-Up
LampBK At Lamp 12
Right City
Lamp
(Built-Up-
Export)GY Right
Headlamp
OpeningN/S
Right Front
Door SpeakerBK At
Passengers
Door15
Right Front
Fog LampBK At Lamp N/S
Right Front
Side Marker
LampNAT At Lamp N/S
Right Front
Turn Signal
Lamp
(Built-Up-
Export)NAT At Lamp 3
Right Front
Wheel Speed
SensorBK At Right Front
Wheel
Opening1, 3
Right
HeadlampBK At Lamp 3
Right
Headlamp
Leveling Motor
(Built-Up-
Export)GY Rear of Right
HeadlampN/S
Right
Instrument
Panel SpeakerBK At Speaker 6, 7Connector
Name/NumberColor Location Fig.
Right License
Lamp
(Built-Up-
Export)NAT At Lamp 13
Right
Park/Turn
Signal Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Right Rear
Door Lock
MotorBK At Motor 16
Right Rear
Fog Lamp
(Built-Up-
Export)GY At Lamp 13
Right Rear
SpeakerBK At Speaker 11
Right Rear
Turn Signal
Lamp
(Built-Up-
Export)GY At Lamp 12
Right Rear
Wheel Speed
SensorBL At Right Rear
Wheel
OpeningN/S
Right
Repeater
Lamp
(Built-Up-
Export)BL At Lamp 1
Right Tail/Stop
Lamp
(Built-Up-
Export)BK At Lamp 12
Right
Tail/Stop/ Turn
Signal Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Seat Belt
SwitchBK Under Drivers
SeatN/S
Sentry Key
Immobilizer
ModuleBK Left Side of
Instrument
Panel6
Siren
(Built-Up-
Export)Left Front of
Vehicle1
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Sunroof
Control
ModuleAt Sunroof N/S
Sunroof Motor At Sunroof N/S
Sunroof
SwitchBK At Switch N/S
Sunroof Vent
SwitchAt Switch N/S
Throttle
Position
SensorBK On Throttle
Body2
Torque
Converter
Clutch
Solenoid
(ATX)BK On
Transmission2
Traction
Control SwitchWT Center of
Instrument
Panel7Connector
Name/NumberColor Location Fig.
Trunk Key
Cylinder
SwitchGY On Decklid 17
Underhood
LampBK At Lamp N/S
Vehicle Speed
Control ServoBK At Right Front
Strut Tower1, 3
Vehicle Speed
SensorBK On
Transmission5
Windshield
Washer PumpRD At Right Front
Wheel
Opening1
Wipe/Wash
SwitchGY Center of
Instrument
Panel6
Wiper Motor BK Left Side of
Engine
CompartmentN/S
8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Oxygen
Sensor 1/2
Downstream
(2.0L)GY Right Rear of
Engine22
Park/Neutral
Position
Switch (ATX)BK On
TransmissionN/S
Passenger
AirbagYL Left Side of
Instrument
Panel25
Passenger
Cylinder Lock
SwitchBK At
Passengers
Door33
Passenger
Door Lock
MotorBK At
Passengers
Door33
Passenger
Door Lock
SwitchBK At
Passengers
Door33
Passenger
Power MirrorBL At
Passengers
Door33
Passenger
Power
Window MotorBK At
Passengers
Door33
Passenger
Power
Window
SwitchGY At
Passengers
Door33
Power Mirror
SwitchGY At Drivers
Door34
Power
Steering
Pressure
SwitchGY Left Rear of
Engine
CompartmentN/S
Powertrain
Control
Module - C1BK Left Fender
Side Shield21
Powertrain
Control
Module - C2BK Left Fender
Side Shield19
PRNDL Lamp BK At Center
Console25
Proportional
EVAP/Purge
SolenoidBK Left Rear of
Engine
Compartment19
Radiator Fan
MotorBK Front of
Engine
Compartment19Connector
Name/NumberColor Location Fig.
Radio - C1 BK Rear of Radio 24
Radio - C2 GY Rear of Radio 24
Rear Window
Defogger
SwitchBK Center of
Instrument
Panel24
Remote
Keyless Entry
ModuleBK Center of
Instrument
Panel24
Right Back-Up
LampBK At Lamp 31
Right City
LampGY At Lamp N/S
Right Front
Door SpeakerBK At Drivers
Door34
Right Front
Fog LampBK At Lamp N/S
Right Front
Turn Signal
LampNAT At Lamp 20
Right Front
Wheel Speed
SensorBK At Right Front
Wheel
Opening20
Right
HeadlampBK At Lamp 20
Right
Headlamp
Leveling MotorGY Rear of right
HeadlampN/S
Right
Instrument
Panel SpeakerBK At Speaker 25
Right License
LampNAT At Lamp 32
Right Rear
Door Lock
MotorBK At Motor 35
Right Rear
Fog LampGY At Lamp 32
Right Rear
SpeakerBK At Speaker 30
Right Rear
Turn Signal
LampGY At Lamp 31
Right Rear
Wheel Speed
SensorBL At Right Rear
Wheel
OpeningN/S
Right
Repeater
LampBL At Lamp 18
8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Right Tail/Stop
LampBK At Lamp 31
Seat Belt
SwitchBK Under Drivers
SeatN/S
Sentry Key
Immobilizer
ModuleBK Right Side of
Instrument
Panel25
Siren Left Front of
Vehicle18
Sunroof
Control
ModuleAt Sunroof N/S
Sunroof Motor At Sunroof N/S
Sunroof
SwitchBK At Switch N/S
Sunroof Vent
SwitchAt Switch N/S
Throttle
Position
SensorBK On Throttle
Body19
Torque
Converter
Clutch
Solenoid
(ATX)BK On
Transmission19Connector
Name/NumberColor Location Fig.
Traction
Control SwitchWT Center of
Instrument
Panel24
Trunk Key
Cylinder
SwitchGY On Decklid 36
Underhood
LampBK At Lamp N/S
Vehicle Speed
Control ServoBK At Left Front
Strut Tower19
Vehicle Speed
SensorBK On
Transmission22
Windshield
Washer PumpRD At Right Front
Wheel
Opening18
Wipe/Wash
SwitchGY Center of
Instrument
Panel25
Wiper Motor BK Right Side of
Engine
Compartment23
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25
DESCRIPTION AND OPERATION (Continued)

(2) Apply MopartSilicone Rubber Adhesive Seal-
ant at the oil pump to engine block parting line (Fig.
83).
(3) Position a new oil pan gasket onto pan.
(4) Install oil pan and tighten screws to 12 N´m
(105 in. lbs.).
(5) Install transaxle dust cover (Fig. 82).
(6) Install lateral bending brace (Fig. 82).(7) Install structural collar. Refer to procedure in
this section.
(8) Install oil filter adaptor and tighten assembly
to 80 N´m (60 ft. lbs.) (Fig. 81).
(9) Install oil filter.
(10) Lower vehicle and fill engine crankcase with
proper oil to correct level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(2) Remove crankshaft damper. Refer to procedure
in this section.
(3) Remove front timing belt cover and timing belt.
Refer to procedures in this section.
(4) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 84).
(5) Remove crankshaft sprocket key from crank-
shaft (Fig. 85).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 81 Oil Filter Adaptor
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 82 Bending Brace, Structural Collar, and Dust
Cover
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 83 Oil Pan Sealing
1 ± PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING
LINE OF THE OIL PUMP TO ENGINE BLOCK
Fig. 84 Crankshaft SprocketÐRemoval
1 ± SPECIAL TOOL 6793
2 ± SPECIAL TOOL C-4685-C2
3 ± CRANKSHAFT SPROCKET
9 - 48 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(6) Using Special Tool 6771, remove front crank-
shaft oil seal (Fig. 86). Do not damage the seal con-
tact area on the crankshaft.
INSTALLATION
(1) Position seal into opening with seal spring
towards the inside of engine. Using Special Tool
6780-1 (Fig. 87), install seal until flush with cover.
(2) Install crankshaft sprocket key (Fig. 85).
(3) Install crankshaft sprocket (Fig. 88) using Spe-
cial Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing outward.NOTE: Use of Special Tool 6792 is required to set
proper crankshaft sprocket depth for proper timing
belt tracking.
Fig. 85 Crankshaft Key
1 ± CRANKSHAFT KEY
Fig. 86 Front Crankshaft Oil SealÐRemoval
1 ± SPECIAL TOOL 6771
Fig. 87 Front Crankshaft Oil SealÐInstallation
1 ± PROTECTOR
2 ± SEAL
3 ± SPECIAL TOOL 6780±1
4 ± INSTALLER
Fig. 88 Crankshaft SprocketÐInstallation
1 ± SPECIAL TOOL 6792
PL2.0L SOHC ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)

FUEL TUBES/LINES/HOSES AND CLAMPS
OPERATION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes areproperly routed to prevent pinching and to avoid heat
sources.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Tighten hose clamps to 3 N´m (25 in. lbs.) torque.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(5) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(6) Return fuel pump relay to PDC.
(7) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
INJECTOR CONNECTOR
REMOVAL
(1) Disconnect electrical connectors at the fuel
injectors. To remove connector refer to (Fig. 8). Pull
the red colored slider away from injector (1). While
pulling the slider, depress tab (2) and remove connec-
tor (3) from injector. The factory fuel injection wiring
harness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, make note of wiring location before removal.
Fig. 6 Plastic Quick-Connect Fittings
1 ± CASING
2 ± WINDOW
3 ± RETAINER TAB
4 ± NIPPLE
5 ± O RINGS
6 ± WINDOW
7 ± RETAINER ªEARº
14 - 8 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

DESCRIPTION AND OPERATION
INJECTION SYSTEM
All engines used in this section have a sequential
Multi-Port Electronic Fuel Injection system. The MPI
system is computer regulated and provides precise
air/fuel ratios for all driving conditions. The Power-
train Control Module (PCM) operates the fuel injec-
tion system.
The PCM regulates:
²Ignition timing
²Air/fuel ratio
²Emission control devices
²Cooling fan
²Charging system
²Idle speed
²Vehicle speed control
Various sensors provide the inputs necessary for
the PCM to correctly operate these systems. In addi-
tion to the sensors, various switches also provide
inputs to the PCM.
All inputs to the PCM are converted into signals.
The PCM can adapt its programming to meet chang-
ing operating conditions.
Fuel is injected into the intake port above the
intake valve in precise metered amounts through
electrically operated injectors. The PCM fires the
injectors in a specific sequence. Under most operat-
ing conditions, the PCM maintains an air fuel ratio
of 14.7 parts air to 1 part fuel by constantly adjust-
ing injector pulse width. Injector pulse width is the
length of time the injector is open.
The PCM adjusts injector pulse width by opening
and closing the ground path to the injector. Engine
RPM (speed) and manifold absolute pressure (air
density) are the primary inputs that determine injec-
tor pulse width.
MODES OF OPERATION
OPERATION
As input signals to the PCM change, the PCM
adjusts its response to output devices. For example,
the PCM must calculate a different injector pulse
width and ignition timing for idle than it does for
Wide Open Throttle (WOT). There are several differ-
ent modes of operation that determine how the PCM
responds to the various input signals.
There are two different areas of operation, OPEN
LOOP and CLOSED LOOP.
During OPEN LOOP modes the PCM receives
input signals and responds according to preset PCM
programming. Inputs from the upstream and down-
stream heated oxygen sensors are not monitored dur-
ing OPEN LOOP modes, except for heated oxygensensor diagnostics (they are checked for shorted con-
ditions at all times).
During CLOSED LOOP modes the PCM monitors
the inputs from the upstream and downstream
heated oxygen sensors. The upstream heated oxygen
sensor input tells the PCM if the calculated injector
pulse width resulted in the ideal air-fuel ratio of 14.7
to one. By monitoring the exhaust oxygen content
through the upstream heated oxygen sensor, the
PCM can fine tune injector pulse width. Fine tuning
injector pulse width allows the PCM to achieve opti-
mum fuel economy combined with low emissions.
For the PCM to enter CLOSED LOOP operation,
the following must occur:
(1) Engine coolant temperature must be over 35ÉF.
²If the coolant is over 35É the PCM will wait 44
seconds.
²If the coolant is over 50ÉF the PCM will wait 38
seconds.
²If the coolant is over 167ÉF the PCM will wait
11 seconds.
(2) For other temperatures the PCM will interpo-
late the correct waiting time.
(3) O2 sensor must read either greater than 0.745
volts or less than 0.1 volt.
(4) The multi-port fuel injection systems has the
following modes of operation:
²Ignition switch ON (Zero RPM)
²Engine start-up
²Engine warm-up
²Cruise
²Idle
²Acceleration
²Deceleration
²Wide Open Throttle
²Ignition switch OFF
(5) The engine start-up (crank), engine warm-up,
deceleration with fuel shutoff and wide open throttle
modes are OPEN LOOP modes. Under most operat-
ing conditions, the acceleration, deceleration (with
A/C on), idle and cruise modes,with the engine at
operating temperatureare CLOSED LOOP modes.
IGNITION SWITCH ON (ZERO RPM) MODE
When the ignition switch activates the fuel injec-
tion system, the following actions occur:
²The PCM monitors the engine coolant tempera-
ture sensor and throttle position sensor input. The
PCM determines basic fuel injector pulse width from
this input.
²The PCM determines atmospheric air pressure
from the MAP sensor input to modify injector pulse
width.
When the key is in the ON position and the engine
is not running (zero rpm), the Auto Shutdown (ASD)
and fuel pump relays de-energize after approximately
14 - 22 FUEL SYSTEMPL