belt DODGE NEON 2000 Service User Guide

CONDITION POSSIBLE CAUSE CORRECTION
INADEQUATE HEATER
PERFORMANCE.1. Has a diagnostic trouble code
(DTC) been set?1. Refer to On-Board Diagnostic in
Group 25, Emission Control
Systems.
2. Coolant level low. 2. Refer to testing cooling system
for leaks in this section. Repair as
necessary.
3. Obstructions in heater hose
fittings at engine.3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping
coolant to heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch. The water pump drive belt
may be slipping causing poor water
pump operation.5. Refer to water pump in this
section. Repair as necessary.
HEAT ODOR 1. Various heat shields are used at
certain driveline components. One
or more of these shields may be
missing.1. Locate missing shields and
replace or repair as necessary.
2. Is temperature gauge reading
above the normal range?2. Refer to the previous
Temperature Gauge Reads High in
these Diagnostic Charts. Repair as
necessary.
3. Is cooling fan operating
correctly?3. Refer to Cooling System Fan in
this section for diagnosis. Repair as
necessary.
4. Has undercoating been applied
to any unnecessary component.4. Clean undercoating as necessary.
5. Engine may be running rich
causing the catalytic converter to
overheat.5. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN). GAUGE MAY BE READING
LOW1. For proper driveability, good
vehicle emissions and for
preventing build-up of engine oil
sludge, the thermostat must be
operating properly. Has a diagnostic
trouble code (DTC ) been set?1. Refer to On-Board Diagnostics in
Group 25, Emission Control
Systems. DTC's may also be check
using the DRB scan tool. Refer to
the proper Powertrain Diagnostic
Procedure manual for checking the
thermostat if necessary.
7 - 12 COOLING SYSTEMPL
DIAGNOSIS AND TESTING (Continued)

ENGINE THERMOSTAT TESTING
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolant
reaches a predetermined temperature the wax pellet
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Coolant leakage into the pellet will cause a thermo-
stat to fail open. Do not attempt to free up a thermo-
stat with a screwdriver.
The thermostat that opens too soon type failure
mode is included in the on-board diagnosis. Thecheck engine light will not be lit by an open too soon
condition. If it has failed open, a diagnostic trouble
code (DTC) will be set. Do not change a thermostat
for lack of heater performance or temperature gauge
position, unless a DTC is present. See Diagnosis for
other probable causes. Thermostat failing shut is the
normal long term mode of failure, and normally, only
on high mileage vehicles. The temperature gauge will
indicate this. Refer to Diagnosis in this section.
ACCESSORY DRIVE BELT DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
BELT SLIPPAGE 1. Belt slipping because of
insufficient tension.1. Retension generator belt.
Replace the power steering belt's
automatic belt tensioner.
2. Belt excessively glazed or
hardened from heat and excessive
slippage.2. Replace belt.
3. Incorrect belt. 3. Replace belt.
4. Driven component bearing
failure.4. Replace faulty component.
5. Belt or pulley subjected to
substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.5. Replace belt and clean pulleys.
BELT NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE)1. Belt slippage. 1. Retension generator belt, replace
belt, or automatic belt tensioner.
2. Foreign material imbedded in
belt.2. Replace belt.
3. Non-uniform belt. 3. Replace belt.
4. Misaligned pulley(s). 4. Align accessories.
5. Non-uniform groove or eccentric
pulley.5. Replace pulley(s).
6. Bearing noise. 6. Locate and repair.
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt. 1. Replace belt.
2. Belt tension too loose, or too
tight.2. Retension generator belt.
Replace the power steering belt's
automatic belt tensioner.
3. Misaligned pulleys. 3. Align accessories.
4. Non-uniform grooves or eccentric
pulley.4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects in
groove.
7 - 14 COOLING SYSTEMPL
DIAGNOSIS AND TESTING (Continued)

COOLING SYSTEMÐDRAINING
NOTE: Drain, flush, and fill the cooling system at
the mileage or time intervals specified in Group 0,
Lubrication and Maintenance. If the solution is dirty,
rusty, or contains a considerable amount of sedi-
ment; clean and flush with a reliable cooling system
cleaner. Care should be taken in disposing of the
used engine coolant from your vehicle. Check gov-
ernmental regulations for disposal of used engine
coolant.
Without removing radiator pressure cap and
with system not under pressure:
(1) Shut engine off and turn draincock counter-
clockwise to open (Fig. 18).
(2) The coolant reserve tank should empty first,
then remove the pressure cap. (if not, Refer to Test-
ing Cooling System for leaks).
COOLING SYSTEMÐREFILLING
First clean system to remove old glycol, see Cooling
System Cleaning.
Fill system with 50/50 glycol/water mix. Use anti-
freeze described in Coolant section.
Continue filling system until full, this provides bet-
ter heater performance.Be careful not to spill
coolant on drive belts or the generator.
Fill coolant reserve/recovery system to at least the
FULL HOT mark with 50/50 solution. It may be nec-
essary to add coolant to the reserve/recovery con-
tainer after three or four warm-up/cool down cycles
to maintain coolant level between the FULL HOT
and ADD marks; if any trapped air was removed
from the system.
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL
(1) Raise vehicle on a hoist. Remove right inner
splash shield.
(2) Remove accessory drive belts. Refer to proce-
dure in this section.
(3) Drain cooling system. Refer to Cooling System
Draining in this section.
(4) Remove power steering pump attaching bolts
and set pump and assembly aside. Power steering
lines do not need to be disconnected.
(5) Remove upper and lower torque isolator struts.
(6) Support engine from the bottom and remove
right engine mount attaching bolt.
(7) Remove right engine mount bracket.
(8) Remove timing belt and timing belt tensioner.
Refer to Group 9, Engine for procedures.
(9) Remove camshaft sprocket and rear timing belt
cover. Refer to Group 9, Engine for procedures.
(10) Remove water pump attaching screws to
engine and remove pump (Fig. 19).
INSTALLATION
(1) Apply MopartDielectric Grease to O-ring
before installation.
(2) Install new O-ring gasket in water pump body
O-ring groove (Fig. 20).
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring, resulting in a coolant leak.
(3) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.
Fig. 18 Cooling System Drain Cock Location
1 ± DRAIN COCKFig. 19 Water Pump
1 ± CYLINDER BLOCK
2 ± PUMP BODY
PLCOOLING SYSTEM 7 - 19
SERVICE PROCEDURES (Continued)

(4) Rotate pump by hand to check for freedom of
movement.
(5) Install rear timing belt cover and camshaft
sprocket.
(6) Install timing belt tensioner and timing belt.
Refer to Group 9, Engine for procedure.
(7) Install right engine mount bracket. Refer to
Group 9, Engine for procedure.
(8) Install upper and lower torque isolator struts.
Refer to Group 9, Engine for procedure.
(9) Fill cooling system. Refer to procedures in this
section.
(10) Install accessory drive belts. Refer to proce-
dure in this section.
(11) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
WATER PUMP INLET TUBE
The inlet tube connects the water pump to the
radiator and heater core. This tube is sealed by an
O-ring and held in place by fasteners to the block.
REMOVAL
CAUTION: Do not use any sharp tools to remove
hoses from inlet tube. This may cause the tube to
leak.
(1) Drain cooling system. Refer to procedure in
this section.
(2) Remove upper radiator hose to access the hose
connections at the inlet tube.(3) Remove intake manifold. Refer to Group 9,
Engine for procedure.
(4) Remove lower radiator hose and heater hose
from the inlet tube.
(5) Remove lower intake manifold support bracket.
(6) Remove the inlet tube to the block fasteners.
(7) Rotate tube while removing the tube from the
engine block (Fig. 21).
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 21). Replace
O-ring as necessary.
(2) Lubricate O-ring with MopartDielectric
Grease and install inlet tube into the cylinder block
opening.
(3) Install inlet tube fasteners and tighten fasten-
ers to 12 N´m (105 in. lbs.).
(4) Install intake manifold lower support bracket
fasteners and tighten to 12 N´m (105 in. lbs.).
(5) Connect lower radiator hose and heater hose to
inlet tube.
(6) Install intake manifold. Refer to Group 9,
Engine for procedure.
(7) Install upper radiator hose.
(8) Fill cooling system. Refer to procedure in this
section.
(9) Pressure system to 104 kPa (15 psi) to check
for leaks.
ENGINE THERMOSTAT
REMOVAL
(1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery/reserve system hose
and upper radiator hose.
Fig. 20 Water Pump Body
1 ± IMPELLER
2 ± PUMP BODY
3 ± O-RING
Fig. 21 Water Pump Inlet Tube
1 ± O-RING
2 ± WATER PUMP INLET TUBE
FRONT
7 - 20 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(2) Connect recovery hose to water outlet connec-
tor/thermostat housing (Fig. 29).
(3) Fill container to proper level. Refer to Cooling
System Refilling in this section.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Draining in this section for
procedure.
(2) Detach power cord plug from heater (Fig. 31).
(3) Loosen screw in center of heater. Remove
heater assembly (Fig. 31).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward (Fig. 31).
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Connect power cord to block heater (Fig. 31).
(5) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks.
ACCESSORY DRIVE BELTS
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
REMOVAL
(1) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be removed from
power steering pump pulley. Gently, release spring
tension on tensioner.
(2) Remove belt (Fig. 34).
INSTALLATION
(1) Install belt (Fig. 34) over all pulleys except for
the power steering pump pulley.
(2) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be installed onto
power steering pulley. Release spring tension onto
belt.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 35). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
Fig. 31 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
Fig. 32 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
7 - 24 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

GENERATOR BELT
REMOVAL
(1) Remove power steering pump/air conditioning
compressor drive belt.
(2) Loosen pivot bolt, then locking nut and adjust-
ing bolt (Fig. 36).
(3) Remove generator belt.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
INSTALLATION
(1) Install belt and/or adjust belt tension by tight-
ening adjusting bolt. Adjust belt to specification
shown in Belt Tension Chart.
NOTE: Due to space limitations, the use of a belt
tension gauge is limited. Therefore, measure the
belt deflection at the center span of the generator
belt. Refer to Belt Tension Chart for specifications.
(2) Tighten pivot bolt to 54 N´m (40 ft. lbs.) and
locking nut to 54 N´m (40 ft. lbs.) (Fig. 36).
Fig. 33 Accessory BeltÐRemoving
1 ± 17mm WRENCH
Fig. 34 Power Steering/Air Conditioning Belt
1 ± BELT
2 ± P/S PULLEY
3 ± TENSIONER PULLEY
4 ± CRANKSHAFT PULLEY
5 ± BELT6 ± P/S PULLEY
7 ± TENSIONER PULLEY
8 ± A/C PULLEY
9 ± CRANKSHAFT PULLEY
PLCOOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)

(3) Install power steering pump and A/C compres-
sor drive belt.
AUTOMATIC BELT TENSIONER & PULLEY
The automatic belt tensioner (Fig. 37) maintains
proper tension on the power steering and air condi-
tioning belt. The tensioner is serviced with the
engine mount bracket assembly. The tensioner pulley
can be serviced.
NOTE: Slight axial movement of the tensioner arm
is normal. Tensioner arm should move freely and
maintain 50±70 lb. tension on belt.
REMOVAL
(1) Remove engine mount bracket assembly. Refer
to Group 9, Engine for procedure.
(2) Remove tensioner pulley mounting bolt.
(3) Remove pulley.
INSTALLATION
(1) Install tensioner pulley and bolt. Tighten bolt
to 27 N´m (20 ft. lbs.).
(2) Install engine mount bracket assembly. Refer
to Group 9, Engine for procedure.
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE
The cooling fan module consist of the following
three components: fan, fan motor, and shroud.
Fig. 35 Belt Length Indicator Marks
1 ± AUTOMATIC BELT TENSIONER
2 ± BELT LENGTH INDICATOR
3 ± MAXIMUM BELT LENGTH
4 ± NOMINAL BELT LENGTH
5 ± MINIMUM BELT LENGTH
Fig. 36 Generator Belt Adjustment
1 ± ADJUSTING BOLT
2 ± LOCKING NUT
3 ± PIVOT BOLT
BELT TENSION CHART
Accessory
Drive BeltBelt Tension Belt Deflection
at Center Span*
Power Steering
Pump and A/C
CompressorDynamic Tensioner
GeneratorNew 135 lb. 4.5 mm (0.18 in.)
Used 100 lb. 5.5 mm (0.22 in.)
* Belt deflection is measured at the center of the belt
span with 4.5 kg (10 lb.) force.
7 - 26 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

FAN
There are no repairs to be made to the fan. If the
fan is warped, cracked, or otherwise damaged, it
must be replace withonlythe recommended part for
adequate strength, performance and safety.
REMOVAL
(1) Remove cooling fan module. Refer to procedure
in this section.
(2) Remove fan hub retaining nut (Fig. 38).
(3) Remove fan from motor shaft.
INSTALLATION
(1) Install fan on motor shaft.
(2) Install fan retaining nut and tighten to 3.8
N´m (34 in. lbs.) (Fig. 38).
(3) Install cooling fan module. Refer to procedure
in this section.
FAN MOTOR
REMOVAL
(1) Remove cooling fan module. Refer to procedure
in this section.
(2) Remove fan from motor shaft.
(3) Remove screw attaching the in-rush current
suppressor (Fig. 39).
(4) Remove screws attaching motor to shroud (Fig.
39).
(5) Remove fan motor.INSTALLATION
(1) Install fan motor on shroud and tighten screws
to 3.8 N´m (34 in. lbs.) (Fig. 39).
(2) Install screw attaching the in-rush current sup-
pressor and tighten to 2.6 N´m (23 in. lbs.) (Fig. 39).
(3) Install fan on motor shaft.
(4) Install cooling fan module. Refer to procedure
in this section.
Fig. 37 Automatic Belt Tensioner
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
Fig. 38 FanÐRemoval and Installation
1±FAN
2 ± NUT
3 ± SHROUD ASSEMBLY
Fig. 39 Fan MotorÐRemoval and Installation
1 ± FAN MOTOR SCREWS
2 ± IN RUSH CURRENT SUPPRESSOR SCREW
PLCOOLING SYSTEM 7 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

SHROUD
REMOVAL
(1) Remove cooling fan module. Refer to procedure
in this section.
(2) Remove fan and fan motor as previously
described.
INSTALLATION
(1) Install fan motor and fan as previously
described.
(2) Install cooling fan module. Refer to procedure
in this section.
CLEANING AND INSPECTION
WATER PUMP
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
ACCESSORY DRIVE BELT INSPECTION
Belt replacement under any or all of the following
conditions is required, excessive wear, frayed cords or
severe glazing.
Poly-V Belt system may develop minor cracks
across the ribbed side. These minor cracks are con-
sidered normal and acceptable. Cracks parallel are
not (Fig. 40).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
COOLING SYSTEM CAP
Hold the cap in your hand,right side up(Fig. 41).
The vent valve at the bottom of the cap should open
with a slight pull. If the rubber gasket has swollen,
preventing the valve from opening, replace the cap.
If any light can be seen between vent valve and
the rubber gasket, replace the cap.Use only a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures system
pressurization.
COOLING SYSTEM CLEANING
(1) Drain cooling system. Refer to Cooling System
Draining in this section for procedure.
(2) Refill with clean water. Refer to Cooling Sys-
tem Refilling in this section for procedure.
(3) Run engine with radiator cap installed until
upper radiator hose is hot.
(4) Stop engine and drain water from system. If
water is dirty, fill, run and drain the system again
until water runs clear.
RADIATOR FLUSHING
(1) Drain cooling system. Refer to Cooling System
Draining in this section for procedure.
(2) Remove radiator hoses from engine.
(3) Install suitable flushing gun in radiator lower
hose.
(4) Fill radiator with clean water and turn on air
in short blasts.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.
ENGINE FLUSHING
(1) Drain radiator. Refer to Cooling System Drain-
ing in this section for procedure.
(2) Remove hoses from radiator.
Fig. 40 Drive Belt Wear Pattern
1 ± NORMAL CRACKS BELT OK
2 ± NOT NORMAL CRACKS REPLACE BELT
7 - 28 COOLING SYSTEMPL
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Remove engine thermostat and reinstall ther-
mostat housing. A gasket may be needed to seal thehousing to cylinder head because the seal is part of
thermostat.
(4) Install suitable flushing gun to thermostat
housing hose. Turn on water, and when engine is
filled, turn on air, but no higher than 138 kPa (20
psi) in short blasts. Allow engine to fill between
blasts of air. Continue this procedure until water
runs clean.
(5) Install thermostat and fill cooling system.
Refer to Cooling System Refilling in this section for
procedure.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system, using air
pressure in a direction opposite to that of the normal
flow of water. This is only necessary with dirty sys-
tems and evidence of partial plugging.
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor-
rosion products are carried to the radiator and depos-
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be
removed with a two part cleaner (oxalic acid and
neutralizer) available in auto parts outlets. Follow
manufacturers directions for use.
ADJUSTMENTS
BELT TENSION
For belt tension adjustment procedure, refer to
Accessory Drive Belt Removal and Installation proce-
dure.
Fig. 41 Cooling System Pressure Cap
1 ± PRESSURE RATING
2 ± FILLER NECK SEAL
3 ± PRESSURE VALVE
4 ± VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
PLCOOLING SYSTEM 7 - 29
CLEANING AND INSPECTION (Continued)