check engine DODGE NEON 2000 Service Repair Manual

(1) Discharge refrigerant system using recovery/re-
cycling equipment if charge is present.
(2) Disconnect refrigerant lines from A/C compres-
sor. Cap the open lines to prevent moisture from
entering system.
(3) Remove compressor from vehicle.
(4) From suction port on top of compressor, drain
lubricant from compressor.
(5) Add system capacity minus the capacity of
components that have not been replaced. Refer to the
Lubricant Capacity Chart. Add lubricant through the
suction port on compressor. This is not to exceed 180
ml (6.10 oz.) in total.
(6) Install compressor and connect refrigerant
lines. Then evacuate and charge refrigerant system.
SYSTEM LEAK CHECKING
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND
LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with
R-134a. This is accomplished by performing a system
Charge Level-Check or Fill. If while performing this
test A/C liquid line pressure is less than 345 kPa (50
psi) proceed to Empty Refrigerant System Leak Test.
If liquid line pressure is greater than 345 kPa (50
psi) proceed to low refrigerant level leak test. If the
refrigerant system is empty or low in refrigerant
charge, a leak at any line fitting or component seal is
likely. A review of the fittings, lines and components
for oily residue is an indication of the leak location.
To detect a leak in the refrigerant system, perform
one of the following procedures as indicated by the
symptoms.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approx. 28 in Hg.). Deter-
mine if the system holds a vacuum for 15 minutes. If
vacuum is held, a leak is probably not present. If sys-tem will not maintain vacuum level, proceed with
this procedure.
(2) Prepare a.284 Kg. (10 oz.) refrigerant charge to
be injected into the system.
(3) Connect and dispense.284 Kg. (10 oz.) of refrig-
erant into the evacuated refrigerant system.
(4) Proceed to Step 2 of Low Refrigerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Determine if there is any (R-134a) refrigerant
in the system.
(2) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run for five minutes with the system
set to the following:
²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set in 100 percent outside air
²Blower switch in the high A/C position
²A/C in the ON position
²Open all windows
CAUTION: A leak detector designed for R-12 refrig-
erant (only) will not detect leaks in a R-134a refrig-
erant system.
(4) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the drain tube opening or a heat
duct. A R-134a dye is available to aid in leak detec-
tion, use only Chrysler approved refrigerant dye.
If a thorough leak check has been completed with-
out indication of a leak, proceed to System Charge
Level.
REMOVAL AND INSTALLATION
A/C FILTER/DRIER
The filter/drier is mounted in a rubber grommet on
the right side of the engine compartment. The refrig-
erant must be recovered from the A/C system before
replacing the filter/drier assembly.
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION.
24 - 20 HEATING AND AIR CONDITIONINGPL
SERVICE PROCEDURES (Continued)

obtained, add or subtract shims until desired read-
ing is obtained.
(8) Install compressor shaft bolt. Tighten to 17.56
2 N´m (155620 in. lbs.) torque.
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After new clutch installation, cycle the A/C clutch
20 times (5 seconds on and 5 seconds off). During
this procedure, set the system to the A/C mode,
engine rpm at 1500 - 2000, and high blower speed.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher clutch torque
capability.
CONDENSATION DRAIN TUBE
REMOVAL
(1) Raise vehicle.
(2) Locate rubber drain tube on right side of dash
panel (Fig. 30).
(3) Squeeze clamp and remove drain tube.
INSTALLATION
To install, reverse the preceding operation. Check
the drain tube nipple on the heater-A/C housing for
any obstructions.
CONDENSER
The condenser is located in front of the engine
radiator. It has no serviceable parts. If damaged or
leaking, the condenser assembly must be replaced.
WARNING: THE REFRIGERANT MUST BE
REMOVED FROM THE SYSTEM BEFORE REMOV-
ING THE CONDENSER.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from the A/C system.
(2) Remove battery support strut.
(3) Remove refrigerant lines from condenser (Fig.
31).
(4) Remove upper radiator mounts.
(5) Remove condenser to radiator mounting
screws.
(6) Tilt radiator back and remove condenser.
INSTALLATION
For installation, reverse the above procedures.
²Tighten the condenser refrigerant lines to 5 N´m
(45 in lbs).
Fig. 29 Installing Pulley Assembly
1 ± PULLEY ASSEMBLY
2 ± WOOD BLOCK
Fig. 30 Condensate Water Drain Tube ± Typical
1 ± DASH PANEL (UNDER HOOD RIGHT SIDE)
2 ± CLAMP
3 ± CONDENSATE DRAIN TUBE
4 ± NIPPLE-A/C HEATER HOUSING
PLHEATING AND AIR CONDITIONING 24 - 25
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove the wire connector from the low pres-
sure cut-off switch.
(2) Remove the center bolt of refrigerant line
plumbing sealing plate (Fig. 37).
(3) Carefully pull the refrigerant line-sealing plate
assembly from the expansion valve towards front of
vehicle. Do not scratch the expansion valve sealing
surfaces with pilot tubes.
(4) Cover the openings on A/C line-sealing plate
assembly to prevent contamination.
(5) Remove two screws securing the expansion
valve to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket on
the evaporator sealing plate.
(2) Carefully hold the expansion valve to the evap-
orator sealing plate so not to scratch the sealing sur-
face. Install two screws and tighten to 1163 N´m
(100630 in. lbs.).
(3) Remove and replace the aluminum gasket on
the refrigerant line- sealing plate assembly.
(4) Carefully hold the refrigerant line-sealing plate
assembly to the expansion valve. Install bolt and
tighten to 2363 N´m (200630 in. lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
HEATER CORE
Refer to HVAC Housing Disassembly and Assembly
in this section for heater core removal procedure.
HEATER HOSES
CAUTION: When removing hoses from heater core
inlet or outlet nipples DO NOT exert excess pres-
sure. The heater core may become damaged and
leak engine coolant.
NOTE: Review Cooling System Precautions before
proceeding with this operation.
REMOVAL
(1) Drain engine cooling system. Refer to Group 7,
Cooling System.
(2) Using spring tension clamp pliers, remove
clamps at end of heater hose to be removed (Fig. 38).
(3) Carefully rotate hose back and forth while pull-
ing away from connector nipple.INSTALLATION
For installation, reverse the above procedures.
Fig. 37 Expansion Valve - Typical
1 ± ALUMINUM N-GASKET
2 ± PLUMBING SEALING PLATE
3 ± LOW/DIFFERENTIAL PRESSURE CUT-OFF SWITCH
4 ± DASH PANEL
5 ± H-VALVE
6 ± EVAPORATOR SEALING PLATE
7 ± H-VALVE
Fig. 38 Heater Hoses and Clamps
1 ± COWL PANEL
2 ± HEATER HOSE AND CLAMPS
3 ± HEATER CORE TUBES
4 ± HEATER HOSE SUPPLY AND RETURN TUBES
24 - 28 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

(6) Remove expansion valve from evaporator, and
cap fittings.
(7) Remove rubber drain tube extension from con-
densation drain tube.
(8) Disconnect the vacuum harness at the power
brake booster (Fig. 48).
(9) Unsnap and remove the defroster duct (Fig.
49).(10) Remove three retaining nuts located in the
engine compartment, on the dash panel (Fig. 50).
(11) Remove the right side retaining screw (Fig.
51).
(12) Remove remaining nut located on dash panel
stud.
(13) Disconnect the wiring connectors.
(14) Remove assembly from the vehicle.
Fig. 48 HVAC Vacuum Harness
1 ± BRAKE POWER BOOSTER
2 ± A/C VACUUM CHECK VALVE
3 ± VACUUM HARNESS
Fig. 49 HVAC Housing Defroster Duct
1 ± DEFROSTER DUCT
2 ± BODY
3 ± ELECTRICAL CONNECTOR
4 ± HVAC HOUSING
Fig. 50 Dash Panel Retaining Studs
1 ± BLOWER RESISTOR
2 ± EXPANSION VALVE
3 ± DRAIN TUBE
4 ± DASH PANEL
5 ± HEATER HOSES
6 ± RETAINING STUDS
Fig. 51 Housing Screws
1 ± RIGHT SIDE RETAINING SCREW
2 ± EVAPORATOR PROBE GROMMET
3 ± SCREW BOSSES
4 ± DASH PANEL STUD AND NUT
PLHEATING AND AIR CONDITIONING 24 - 33
REMOVAL AND INSTALLATION (Continued)

VIN CODE DECODING
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United states
2 MakeB = Dodge
P = Plymouth
3 Vehicle Type 3 = Passenger Car
4 Pass. Safety E = Restraint System, Active Driver & Passenger Airbags
5 Car Line S = Neon
6 Series2 = Low Line
4 = High Line
7 Body Style6 = 4 Door Sedan
8 Engine C = 2.0 L 4 Cyl. 16V
9 Check Digit See explanation in this section.
10 Model Year Y = 2000
11 Assembly Plant D = Belvidere
12 Thru 17 Vehicle Build Sequence 6 digit number assigned by assembly plant.
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is
attached to the rear facing of the driver's door. This
label indicates date of manufacture (month and
year), Gross Vehicle Weight Rating (GVWR), Gross
Axle Weight Rating (GAWR) front, Gross Axle Weight
Rating (GAWR) rear and the Vehicle Identification
Number (VIN). The Month, Day and Hour of manu-
facture is also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
BODY CODE EMBOSS
The vehicle is equipped with a Body Code Emboss
and it is located on the rear shelf. The emboss is
located in the trunk area on the forward top edge of
the rear shelf panel.
SERVICE PROCEDURES
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the manufacture recommendation
for application and repair procedures.
SPECIFICATIONS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
The graphic symbols illustrated in the following
International Control and Display Symbols chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
Fig. 2 Vehicle Safety Certification Label
2 INTRODUCTIONPL
DESCRIPTION AND OPERATION (Continued)

VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Passenger Safety E = Active Restraints, Driver and Passenger Airbags
5 Car Line S = Neon BUX L. H. D.
V = Neon BUX R. H. D.
6 Series M = DD5 5-Speed Manual Transmission
A = 3-Speed Automatic Transmission
7 Body Style7 = 4 Door Pillared Hardtop
8 Engine C = 2.0L 4 Cyl. 16V SOHC
A = 1.8L 4 Cyl. 16V SOHC
9 Check Digit See explanation in this section.
10 Model Year Y = 2000
11 Assembly Plant D = Belvedere Assembly
12 Thru 17 Build Sequence 6 Digit number assigned by assembly plant
E-MARK LABEL
An E-mark Label (Fig. 3) is located on the rear
shut face of the driver's door. The label contains the
following information:
²Date of Manufacture
²Month-Day-Hour (MDH)
²Vehicle Identification Number (VIN)
²Country Codes
²Regulation Number
²Regulation Amendment Number
²Approval Number
Fig. 3 E-Mark Label
1 ± Country Code
2 ± Regulation Number
3 ± Approval Number
4 ± Amendment Number
2 INTRODUCTIONPL
GENERAL INFORMATION (Continued)