DODGE NEON 2000 Service Repair Manual

(10) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Slide radiator down into position behind radia-
tor support (yoke).
(2) Attach air conditioning condenser to radiator, if
equipped (Fig. 25), with four mounting screws.
Tighten screws to 5.4 N´m (50 in. lbs.). Then seat the
radiator assembly lower rubber isolators into the
mounting holes provided in the lower crossmember.
(3) Install and tighten radiator isolator mounting
bracket screws to 10 N´m (90 in. lbs.) (Fig. 24). The
radiator should have clearance to move up, approxi-
mately 5±8 mm (0.20±0.31 in.) after assembled.
(4) Install lower radiator hose. Align the hose and
position the clamp so it will not interfere with engine
components.
(5) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 2 N´m (18 in. lbs.).
(6) Slide fan module down into clip(s) on lower
radiator flange (Fig. 23). Install retaining screws and
tighten to 7.5 N´m (65 in. lbs.).
(7) Connect the cooling fan motor electrical connec-
tor.
(8) Install upper radiator hose. Align the hose and
position the clamp so they will not interfere with the
engine or the hood.
(9) Connect negative cable to battery.
(10) Fill cooling system with coolant. Refer to pro-
cedure in this section.
(11) Operate engine until it reaches normal operat-
ing temperature. Check cooling system and auto-
matic transmission for correct fluid levels.
RADIATOR DRAINCOCK
REMOVAL
(1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 26) from
the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening.
(2) Tighten the draincock stem by turning clock-
wise to 2.0-2.7 N´m (18-25 in. lbs.).
COOLING FAN MODULE
All models use a single speed electric motor driven
cooling system fan. The fan module includes a motor,
fan blade, and support shroud. The module is fas-
tened to the radiator by screws.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system below upper radiator hose
level. Refer to procedure in this section.
(3) Remove upper radiator hose from radiator (Fig.
27).
(4) Disconnect fan module electrical connector.
(5) Remove fan module screws from radiator (Fig.
28).
(6) Lift fan shroud up and out of lower shroud
attachment clips.
(7) Refer to Disassembly and Assembly in this sec-
tion for fan module sub-component service proce-
dures.
Fig. 25 A/C Condenser to Radiator Mounting Screws
1 ± AIR CONDITIONING CONDENSER TO RADIATOR
MOUNTING SCREWS
2 ± LOWER ISOLATOR MOUNTS
Fig. 26 Draincock
1 ± DRAIN COCK BODY
2 ± DRAIN COCK HOUSING
7 - 22 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install the fan module into the clips on the
lower radiator tank.
(2) Install the fan module retaining screws and
tighten to 7.5 N´m (65 in. lbs.).
(3) Connect fan module electrical connector.For
wiring diagrams of fan motor systems, refer to
Group 8W, Wiring Diagrams.
(4) Install the upper radiator hose to radiator (Fig.
27). Align hose and position clamp so it will not
interfere with the engine or the hood.
(5) Connect negative cable to battery.
(6) Fill cooling system. Refer to procedure in this
section.
COOLANT RECOVERY CONTAINER
REMOVAL
(1) Disconnect recovery hose from water outlet
connector/thermostat housing (Fig. 29).
(2) Remove container attaching fasteners (Fig. 30).
(3) Remove coolant recovery container.
INSTALLATION
(1) Install coolant recovery container and tighten
fasteners to 4 N´m (35 in. lbs.) (Fig. 30).
Fig. 27 Upper Radiator Hose
1 ± UPPER RADIATOR HOSE
2 ± UPPER RADIATOR MOUNTS
Fig. 28 Fan ModuleÐRemoval/Installation
1 ± SCREWS
2 ± LOWER MOUNTS
3 ± FAN MOTOR ELECTRICAL CONNECTOR
Fig. 29 Recovery Container Hose
1 ± RECOVERY HOSE
2 ± ENGINE COOLANT RECOVERY CONTAINER
3 ± PRESSURE CAP
Fig. 30 Coolant Recovery Container
1 ± COOLANT RECOVERY CONTAINER
2 ± SCREW
3 ± NUT
PLCOOLING SYSTEM 7 - 23
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)

SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE SPECIFICATIONSSPECIAL TOOLS
COOLING
6.2 Liters (6.5 qts.)
CAPACITY, Includes Heater and Coolant Reserve
System
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
A/C Condenser to RadiatorÐ
Screws5.4 Ð 50
Automatic Belt Tensioner
PulleyÐBolt27 20 Ð
Coolant Recovery ContainerÐ
Nut/Screw4Ð35
Fan Module to RadiatorÐ
Screws7.2 Ð 65
Fan Motor to ShroudÐScrews 3.8 Ð 34
Fan Blade to Motor ShaftÐ
Nut3.8 Ð 34
In Rush Current SupressorÐ
Screw2.6 Ð 23
Generator MountingÐPivot
Bolt54 40 Ð
Generator MountingÐLocking
Nut54 40 Ð
Radiator (Cooling Module) to
BodyÐScrews10 Ð 90
Thermostat Housing/Water
Outlet ConnectorÐScrews12 Ð 105
Transmission HoseÐClamps 2 Ð 18
Water Pump to Engine
BlockÐBolts12 Ð 105
Water Pump Inlet Tube to
Engine BlockÐBolts12 Ð 105
Hose Clamp Pliers 6094
Coolant Refractometer 8286
7 - 30 COOLING SYSTEMPL

BATTERY
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD).........2
CHARGING TIME REQUIRED................2
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR.........3
BATTERY IGNITION OFF DRAW (IOD).........4
BATTERY LOAD TEST......................6
BATTERY OPEN CIRCUIT VOLTAGE...........7
SERVICE PROCEDURES
BATTERY CHARGING......................7CHARGING COMPLETELY DISCHARGED
BATTERY..............................8
VISUAL INSPECTION......................9
REMOVAL AND INSTALLATION
BATTERY...............................10
BATTERY THERMOWRAP..................10
BATTERY TRAY..........................11
SPECIFICATIONS
BATTERY SPECIFICATIONS................11
TORQUE...............................11
GENERAL INFORMATION
INTRODUCTION
The battery (Fig. 1) stores, stabilizes, and delivers
electrical current to operate various electrical sys-
tems in the vehicle. The determination of whether a
battery is good or bad is made by its ability to accept
a charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid
in the electrolyte is measured as specific gravity
using a hydrometer. The original equipment (OE)
battery is equipped with a hydrometer (test indica-
tor) built into the battery cover. The specific gravity
indicates the battery's state-of-charge. The OE bat-
tery is sealed and water cannot be added.
The battery is vented to release gases that are cre-
ated when the battery is being charged and discharged.
The battery top, posts, and terminals should be cleaned
when other under hood maintenance is performed.
When the electrolyte level is below the top of the
plates, Yellow/Clear in the test Indicator, the battery
must be replaced. The battery must be completely
charged, and the battery top, posts, and cable clamps
must be cleaned before diagnostic procedures are per-
formed.
Fig. 1 Battery Location
1 ± BATTERY
2 ± LEFT STRUT TOWER
3 ± PDC
4 ± THROTTLE BODY
5 ± AIR CLEANER HOUSING
PLBATTERY 8A - 1