coolant temperature DODGE NEON 2000 Service Owner's Manual

2
1
C266
C112
SENSOR TEMPERATURE
COOLANT
ENGINE
SWITCH PRESSURE
OIL
ENGINE
POWERTRAIN
CONTROL
MODULE
26C17565
59 71
A
(8W-40-6)10
A3
BRAKE
WARNING
SWITCHVEHICLE
SPEED
SENSOR
TO
S217
C20C104
67 2
CONTROLLER
ANTI-LOCK
BRAKE
20D25
20
VT/YL
D20
20
LGD21
20
PKK2
20
TN/BKG6
20
GY
G7
20
WT/ORG9
18
GY/BKD25
20
VT/YL
D25
20
VT/YLD25
18
VT/YL
D25
22
VT/YL
SCI
RECEIVESCI
TRANSMITENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNALENGINE
OIL
PRESSURE
SWITCH
SENSE SIGNAL SENSOR TEMPERATURECOOLANTENGINE
VEHICLE
SPEED
SENSOR
SIGNALSENSE SWITCH PRESSUREOIL ENGINE
RED
BRAKE
WARNING
INDICATOR
DRIVER PCI
BUS
BUSPCI
C2 C2
SIGNAL SENSORSPEED VEHICLEG7
20
WT/OR
3C102 C2 C2
B
G101
S112
Z1
18
BK
Z1
18
BK
INDICATOR S104 CONNECTORLINK DATA
(8W-30-7)
(8W-30-2)
(8W-30-2)
(8W-30-4)
(8W-30-7)
(8W-30-8)
(8W-30-13)
(8W-30-8)
(8W-35-2)
(8W-15-3) (8W-15-3) (8W-30-4) (8W-30-4)
PL8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
PLI04005008W-10

INSTRUMENT
CLUSTER
A (8W-40-5)
21
193
AIRBAG
CONTROL
MODULE
FUEL
PUMP
MODULE
MODULE ENTRY
KEYLESS
REMOTEFROM
C104
A12C30512G4
18
DB
G4
18
DB
D25
18
VT/YLD25
20
VT/YLD25
22
VT/YL
D25
22
VT/YL
S217
FUEL
LEVEL
SENSOR
SIGNALPCI
BUS
BUSPCI
BUSPCI
VT/YL22 D25
2
MODULE IMMOBILIZER
KEY
SENTRY
2 7
INSTRUMENT
PANEL
DRIVERS
SPEEDOMETER FUEL
GAUGE
INDICATOR PRESSURE
OIL
LOW BRAKE
WARNING
INDICATOR TRACTION
OFF
INDICATOR AIRBAG
WARNING
INDICATORLOW
FUEL
INDICATOR ABS
INDICATOR CHECK
ENGINE
INDICATOR
GAUGE TEMPERATURE
COOLANT
ENGINE TACHOMETER
ODOMETER/TRIP
INDICATOR AJAR
DOOR TRACTION
CONTROL
OFF
INDICATOR INDICATOR
ENGAGED
CRUISE(8W-43-2)
(8W-30-10)
(8W-39-10)
(8W-39-11) (8W-39-3)
(8W-30-4)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTERPL
008W-10PLI04006

K4
18
BK/LB
POWERTRAIN
CONTROL
MODULE
S130
VEHICLE
SPEED
SENSOR
SENSOR POSITION
CRANKSHAFT
CAMSHAFT
POSITION
SENSOR
C1012
K4
18
BK/LB
BK/LB20 K4
BK/LB20 K4
S113SENSOR KNOCKSENSOR PRESSURE
ABSOLUTE
MANIFOLD
ENGINE
COOLANT
TEMPERATURE
SENSOR
43C2
11
22 2
2
K4
20
BK/LBK4
20
BK/LBK4
18
BK/LBK4
20
BK/LBK4
20
BK/LB
(8W-30-8)
(8W-30-3)(8W-30-7)
(8W-30-7) (8W-30-6)(8W-30-6)
(8W-30-7)
(8W-30-6)
PL8W-70 SPLICE INFORMATION 8W - 70 - 3
PLI07003008W-10

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................8W-80-4
A/C Cycling Switch...................8W-80-4
A/C Heater Blower Motor..............8W-80-4
A/C Heater Control...................8W-80-4
A/C High Pressure Switch.............8W-80-4
A/C Low Pressure Switch..............8W-80-5
Airbag Control Module................8W-80-5
Back-Up Lamp Switch................8W-80-5
Blower Motor Resistor Block...........8W-80-6
Brake Lamp Switch..................8W-80-6
Brake Shift Interlock Solenoid..........8W-80-6
Brake Warning Indicator Switch........8W-80-6
C101..............................8W-80-7
C102..............................8W-80-7
C103..............................8W-80-8
C104..............................8W-80-9
C105.............................8W-80-10
C106.............................8W-80-10
C107.............................8W-80-10
C108.............................8W-80-10
C109.............................8W-80-11
C110 .............................8W-80-11
C111 .............................8W-80-11
C201.............................8W-80-12
C202.............................8W-80-13
C203.............................8W-80-13
C204.............................8W-80-13
C205.............................8W-80-14
C301.............................8W-80-15
C302.............................8W-80-15Component Page
C303.............................8W-80-15
C304.............................8W-80-15
C305..........................8W-80-16, 17
C306.............................8W-80-17
Camshaft Position Sensor.............8W-80-18
Cargo Lamp.......................8W-80-18
Center High Mounted Stop Lamp.......8W-80-18
Center Stack Lamp..................8W-80-18
Cigar Lighter/Power Outlet............8W-80-18
Clockspring........................8W-80-19
Clutch Interlock Switch..............8W-80-19
Controller Anti-Lock Brake............8W-80-19
Crankshaft Position Sensor............8W-80-20
Data Link Connector.................8W-80-20
Decklid Solenoid....................8W-80-20
Dome Lamp.......................8W-80-20
Dome Lamp/Intrusion Sensor..........8W-80-21
Driver Airbag......................8W-80-21
Driver Cylinder Lock Switch...........8W-80-21
Driver Door Lock Motor..............8W-80-21
Driver Door Lock Switch..............8W-80-21
Driver Power Mirror.................8W-80-22
Driver Power Window Motor...........8W-80-22
Driver Power Window Switch..........8W-80-23
Engine Coolant Temperature Sensor.....8W-80-23
Engine Oil Pressure Switch...........8W-80-24
Fuel Injector No. 1..................8W-80-24
Fuel Injector No. 2..................8W-80-24
Fuel Injector No. 3..................8W-80-24
Fuel Injector No. 4..................8W-80-24
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 K2 20TN/BK
ENGINE COOLANT
TEMPERATURE
SENSOR
BLACK
SWITCH - C2WINDOW DRIVER POWERQ16 14BR/WT 8 6
Q16 14BR/WT 5
Q26 14VT/WT 5
F21 14TN 4
Z8 14BK/VT 3
Z8 14BK/VT 2
1
5 81 4
GRAYCAV CIRCUIT FUNCTION
-
GROUND
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN)
MASTER WINDOW SWITCH RIGHT FRONT DOWN
MASTER WINDOW SWITCH RIGHT FRONT UP
FUSED IGNITION SWITCH OUTPUT (RUN) -
GROUND
7
Z14 18BK/YL
8 Q26 14VT/WTF20 20WT
RHD LHD
2 1
MASTER WINDOW SWITCH RIGHT FRONT UP
MASTER WINDOW SWITCH RIGHT FRONT DOWN
GROUND Z14 18BK/YL F20 20WT
Q21 14WT/LB 8
DRIVER WINDOW DRIVER DOWN Z14 18BK/YL
7
GROUND -
DRIVER WINDOW DRIVER UP FUSED IGNITION SWITCH OUTPUT (RUN) DRIVER WINDOW DRIVER UP DRIVER WINDOW DRIVER DOWN FUSED IGNITION SWITCH OUTPUT (RUN) GROUND GROUND- FUNCTION CIRCUIT CAV
BLACK
41
85
1
2 Z8 14BK/VT
3 Z8 14BK/VT
4 F21 14TN
5 Q21 14WT/LB
5 Q11 14LB
6
8 Q11 14LBDRIVER POWER
WINDOW
SWITCH - C1
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23
PLI08023008W-10

HEATED OXYGEN SENSOR RELAY CONTROL FUEL INJECTOR NO. 2 DRIVER FUEL INJECTOR NO. 4 DRIVER
37MAP SENSOR SIGNAL 20DG/RD K1 36MODULE - C1CONTROL POWERTRAIN
25
26 K2 20TN/BK
27
28 - -
29 - -
30 K41 20BK/DG OXYGEN SENSOR 1/1 SIGNAL
31
32 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
34
35 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
38 C20 18BR/OR A/C SWITCH SENSE
39 - -
40
BLACK
10 120 1130 2140 31
KNOCK SENSOR SIGNAL 20DB/LG K42 24CLUTCH SWITCH K119 18LG/BK 23- - 22- - 21FUSED IGNITION SWITCH OUTPUT (ST-RUN) 18DB/WT F12
20- - 19K79 18OR/RD 1818TN K12 1718LB/BR K14 16- - 15- - 14FUEL INJECTOR NO. 1 DRIVER 18WT/DB K11 13 12 11GROUND 18BK/TN Z12 10- - 9GENERATOR FIELD DRIVER (+) K20 18DG 8FUEL INJECTOR NO. 3 DRIVER 18YL/WT K13 7AUTOMATIC SHUT DOWN RELAY OUTPUT 18DG/OR A142 6SPEED CONTROL POWER SUPPLY 20YL/RD V32 5 4IGNITION COIL NO. 2 DRIVER 18DB/TN K17 3 2- - 1FUNCTION CIRCUIT CAV
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL --
--
K19 18BK/GY IGNITION COIL NO. 1 DRIVER
ENGINE OIL PRESSURE SWITCH SENSE G6 20GY
K127 18BK/OR
OXYGEN SENSOR GROUND
20TN K90 ENGINE STARTER MOTOR RELAY CONTROL
--
--
SPEED CONTROL- - --
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37
PLI08037008W-10

Connector
Name/NumberColor Location Fig.
C204 RD Left Side of
Instrument
Panel6, 8, 9
C205 GY Left Side of
Instrument
Panel6, 8,
14
C301 RD Right C-Pillar 11
C302 BK Inner Left
Rear Quarter
Panel11
C303 BL/BK Left B-Pillar at
Rear Door10, 16
C304 BL/BK Right B-Pillar
at Rear Door12, 16
C305 NAT Left Side of
Instrument
Panel6, 8,
10
C306 BK Front Center
of Headliner9
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf11
Center High
Mounted Stop
LampBK Rear of Lamp 17
Center Stack
LampBK Center of
Instrument
Panel7
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel7
Clockspring GN Rear of
Steering
Wheel6
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal2
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower2
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK At Left Kick
Panel Area2Connector
Name/NumberColor Location Fig.
Decklid
SolenoidBK On Decklid 17
Dome Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Dome
Lamp/Intrusion
Sensor
(Built-Up-
Export)NAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door14
Driver Door
Lock MotorBK At Drivers
Door14
Driver Door
Lock SwitchBK At Drivers
Door14
Driver Power
MirrorGY At Drivers
Door14
Driver Power
Window MotorBK At Drivers
Door14
Driver Power
Window
Switch - C1BK At Drivers
Door14
Driver Power
Window
Switch - C2GY At Drivers
Door14
Engine
Coolant
Temperature
SensorBK Right Front of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine5
Fuel Injector
NO.1BK At Injector 4
Fuel Injector
NO. 2BK At Injector 4
Fuel Injector
NO. 3BK At injector 4
Fuel Injector
NO. 4BK At Injector 4
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSPL
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)

MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4 oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 1)NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 1)
²Drill motor with 3M RolocyBristle Disc (white
or yellow) (Fig. 1)
CAUTION: Excessive pressure or high RPM can
damage the sealing surfaces. The mild (white, 120
grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
on cast iron surfaces with care.
CRANKSHAFT DAMPER BOLT ACCESS PLUG
An access plug is located in the right splash shield
(Fig. 2). Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 3). With the cup plug rotated, grasp firmly
with pliers or other suitable tool and remove plug
(Fig. 3).
Fig. 1 Proper Tool Usage For Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
9 - 2 ENGINEPL
GENERAL INFORMATION (Continued)

should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
ENGINE OIL LEAK INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
PLENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)