battery DODGE NEON 2000 Service Repair Manual

8W-20 CHARGING SYSTEM
Component Page
Automatic Shut Down Relay............8W-20-2
Battery............................8W-20-2
Engine Starter Motor.................8W-20-2
Fuse 21 (PDC)......................8W-20-2
Fusible Link........................8W-20-2
G104..............................8W-20-2Component Page
G105..............................8W-20-2
Generator..........................8W-20-2
Inlet Air Temperature Sensor...........8W-20-2
Power Distribution Center.............8W-20-2
Powertrain Control Module............8W-20-2
PL8W - 20 CHARGING SYSTEM 8W - 20 - 1

GENERATOR
ENGINE
STARTER
MOTOR
C18
GENERATOR
FIELD
DRIVER (+)POWERTRAIN
CONTROL
MODULE
K20
18
DG
21FUSE20A
21
34
36
POWER
DISTRIBUTION
CENTER BATTERY
A0
6
RD
A0 8RD
Z0
8
BK
Z1
10
BK
G105
A142
18
DG/OR
1C101
A142
18
DG/OR
S122
2
1
RELAY DOWN
SHUT
AUTOMATIC
A14
18
RD/WT
S106
A14
14
RD/WT
(IN PDC)
B(+)
S121
GROUNDSENSOR INLET AIR
TEMPERATURE
SENSOR
SIGNAL GROUNDSENSOR
SIGNAL SENSOR TEMPERATUREINLET AIR
VT/LG20 G31BK/LB20 K4
BK/LB20 K4
1 2
C243C252
S113
RD/WT18 A14
46C2
B(+) FUSED
SENSOR
TEMPERATURE
AIR
INLET
A11
12
BK
BK/GY8 A11
FUSIBLE
LINK
S125
BK/GY8 A11
BK/GY8 A11
G104
(8W-30-2)
(8W-30-6)
(8W-30-11) (8W-10-16)(8W-10-2)
(8W-10-3)
(8W-15-8)
(8W-10-17)
(8W-21-2)(8W-30-2)(8W-10-16)
(8W-10-17)
(8W-30-6)(8W-30-6) (8W-15-8)
8W - 20 - 2 8W-20 CHARGING SYSTEMPL
008W-10PLI02002

8W-21 STARTING SYSTEM
Component Page
Battery............................8W-21-2
Engine Starter Motor.................8W-21-2
Engine Starter Motor Relay............8W-21-2
Fuse 9 (PDC).......................8W-21-2
Fusible Link A11....................8W-21-2Component Page
Generator..........................8W-21-2
Ignition Switch......................8W-21-2
Power Distribution Center.............8W-21-2
Powertrain Control Module............8W-21-2
PL8W - 21 STARTING SYSTEM 8W - 21 - 1

28 26
2524
T40
14
BR
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
6
SWITCH IGNITION
MOTOR STARTER
ENGINE
BR14 T40
30A
FUSE
9
9
A0
6
RD
CENTER DISTRIBUTION
POWER
1 2
A0
8
RD
BATTERY
S125
BK/GY8 A11
GENERATOR
4C102
M
3 LOCK 0 OFF
2 RUN 1 START
2 HOLD-IN 1 PULL-IN A41
14
YL
A41
14
YL23C103B23
C131
POWERTRAIN
CONTROL
MODULE
K90
20
TN
K90
20
TN
6C101
A1
14
RD
B24C10324
A1
14
RD
A1
14
RD
B(+)
STARTER
RELAY
CONTROL
4
1
2
03
7
1
4 ACC
MOTOR ENGINE
A11
12
BK
BK/GY8 A11
FUSIBLE
LINK
BK/GY8 A11
(8W-10-8)(8W-10-2)
(8W-10-3)
(8W-20-2)
(8W-20-2)
(8W-10-8)
(8W-30-15)
8W - 21 - 2 8W-21 STARTING SYSTEMPL
008W-10PLI02102

ST-RUN A21
10 11
FUSE
BLOCK
10A
FUSE
1110FUSE10A
31 30
RHD LHD35
15A
FUSE
15 15
BATT A3BATT A0
13FUSE15A
13
POWER
DISTRIBUTION
CENTER
10 15
INSTRUMENT
CLUSTER
14 21
RKE OTHER
S103
S201 S213 S220
G204
5C103B5
INSTRUMENT PANEL DRIVERSBATTERY
INDICATOR G5
20
DB/WT
G5
20
DB/WT
F33
20
PK/RD
L7
20
BK/YL
L7
20
BK/YLM1
20
PK
M1
20
PK
M1
20
PK
M1
20
PK
S205
Z3
16
BK/OR
Z3
14
BK/OR
MULTI-
FUNCTION
SWITCH
2 HEAD 1 PARK
0 OFF
20
9
HEADLAMP
SWITCH
BUILT-UP-EXPORT
3
2 1 03 REAR FOG
(8W-10-10)
(8W-11-2)
(8W-11-3)
(8W-11-10) (8W-11-10) (8W-11-13)
(8W-11-14)(8W-10-9) (8W-10-7)
(8W-10-12)(8W-10-2)
(8W-10-3)
(8W-10-12)
(8W-10-12) (8W-11-13)
(8W-11-14) (8W-11-10)
(8W-15-11) (8W-15-11)(8W-50-6)
8W - 40 - 2 8W-40 INSTRUMENT CLUSTERPL
008W-10PLI04002

Connector
Name/NumberColor Location Fig.
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment3
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel7, 8
G202 Lower Center
of Instrument
Panel7, 8
G203 Lower Center
of Instrument
Panel7, 8
G204 Lower Center
of Instrument
Panel7, 8
G301 Inner Left
Rear Quarter
Panel11
G302 Inner Right
Rear Quarter
Panel12
G303 Inner Left
Rear Quarter
Panel11
G304 At Decklid 17
Generator BK Left Rear of
Engine5
Glove Box
Lamp/SwitchBK Rear of
Lamp/Switch6, 7
Headlamp
Leveling
Switch
(Built-Up-
Export)BK Center of
Instrument
Panel7
High Note
HornBK Right Inner
Fender1
Hood Ajar
SwitchBK Right Side of
Engine
CompartmentN/SConnector
Name/NumberColor Location Fig.
Idle Air Control
MotorBK On Throttle
Body2
Ignition Coil BK Top of Valve
Cover5
Ignition Switch BK Rear of
Switch6
Inlet Air
Temperature
SensorBK Left Front of
Engine
Compartment2
Instrument
ClusterBK Left Side of
Instrument
Panel6
Knock Sensor BK Left Front of
Engine4
Leak
Detection
Pump (Except
Built-Up-
Export)BK Left Rear of
Vehicle13
Left Back-Up
LampBK At Lamp 11
Left City Lamp
(Built-Up-
Export)BK At Lamp N/S
Left Front
Door SpeakerBK At Drivers
Door14
Left Front Fog
LampBK At Lamp N/S
Left Front Side
Marker Lamp
(Except
Built-Up-
Export)NAT At Lamp N/S
Left Front Turn
Signal Lamp
(Built-Up-
Export)NAT At Lamp 2
Left Front
Wheel Speed
SensorBK At Left Front
Wheel
Opening2
Left Headlamp BK At Lamp 2
Left Headlamp
Leveling Motor
(Built-Up-
Export)GY Rear of Left
HeadlampN/S
Left
Instrument
Panel SpeakerBK At Speaker 6
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
C303 BL/BK Left B-Pillar at
Left Rear
Door28, 35
C304 BL/BK Right B-Pillar
at Right Rear
Door29, 31,
35
C305 NAT Right Side of
Instrument
Panel25, 26,
29
C306 BK Front Center
of Headliner27
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf30
Center High
Mounted Stop
LampBK Rear of Lamp 36
Center Stack
LampBK Center of
Instrument
Panel24
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel24
Clockspring GN Rear of
Steering
Wheel25
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal23
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower19
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK Right Front
Kick Panel23
Decklid
SolenoidBK On Decklid 36
Dome
Lamp/Intrusion
SensorNAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door34
Driver Door
Lock MotorBK At Drivers
Door34Connector
Name/NumberColor Location Fig.
Driver Door
Lock SwitchBK At Drivers
Door34
Driver Power
MirrorBL At Drivers
Door34
Driver Power
Window MotorBK At Drivers
Door34
Driver Power
Window
Switch - C1BK At Drivers
Door34
Driver Power
Window
Switch - C2GY At Drivers
Door34
Engine
Coolant
Temperature
SensorBK Right Side of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine22
Fuel Injector
NO. 1BK At Injector 21
Fuel Injector
NO. 2BK At Injector 21
Fuel Injector
NO. 3BK At injector 21
Fuel Injector
NO. 4BK At Injector 21
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment20
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel24, 26
8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 5). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. Thefollowing is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 5). In addition, suspect areas can be
checked by placing plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the scale pro-
vided on the package. Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications.Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
Fig. 6 Clearance Measurement
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)

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 re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder 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. Remove dipstick (Fig. 7) and observe oil
level. Add oil only when the level is at or below the
ADD mark (Fig. 8).
Fig. 7 Dipstick and Engine Oil Fill Locations
1 ± ENGINE OIL FILL
2 ± ENGINE COOLANT RECOVERY CONTAINER3 ± ENGINE OIL DIPSTICK
4 ± COOLING SYSTEM PRESSURE CAP
Fig. 8 Oil Level
1 ± ENGINE OIL LEVEL DIPSTICK
9 - 6 ENGINEPL
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSIS
TABLE OF CONTENTS
page page
DIAGNOSIS AND TESTING
GENERAL INFORMATION...................8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS......8
CYLINDER COMPRESSION PRESSURE TEST . . . 8
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.........................9LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS............................9
ENGINE OIL LEAK INSPECTION..............9
ENGINE DIAGNOSISÐPERFORMANCE........11
ENGINE DIAGNOSISÐMECHANICAL.........12
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
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 engine RPM'S change, the area of the sus-
pected 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 (689 kPa)
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
9 - 8 ENGINEPL