engine DODGE NEON 2000 Service Owner's Guide

the ignition key to the start position. The engine
starter should crank. If the starter does not crank,
visually inspect the clutch pedal for obstructions
(floor mat, etc.). Also make sure the clutch pedal
blade contacts and fully
Electrical Test
(1) Move ignition key to the ªOFF/LOCKº position
and remove key.
(2) Set park brake.
(3) Disconnect the clutch interlock/upstop switch
connector.
(4) Using an ohmmeter, check for continuity
between terminals2&3with the interlock switchnot depressed (clutch pedal at rest). There should be
no continuity between the terminals (open circuit).
(5) Fully depress the clutch pedal to close the
switch at least 1.25 mm (0.050 in.). The ohmmeter
should show continuity (0 ohms).
(6) If ohmmeter readings do not fall within these
ranges, the switch assembly is defective and should
be replaced. If the switch tests ok, wiring is defective.
Refer to Group 8W, Wiring Diagrams and repair
defective wiring.
UPSTOP SWITCH
Mechanical Test
(1) Raise vehicle on hoist.
(2) Start engine and operate speed control to main-
tain speed.
(3) Depress clutch pedal at least 33 mm (1.30 in.).
Speed control operation should terminate. If speed
control does not terminate, the upstop switch is
defective or the related wiring is shorted. Proceed to
the upstop switch electrical test.
Electrical Test
(1) Move ignition key to the ªOFF/LOCKº position
and remove key.
(2) Set park brake.
(3) Disconnect the clutch interlock/upstop switch
connector.
(4) Using an ohmmeter, check for continuity
between terminals1&2with the upstop switch
depressed (clutch pedal at rest). The ohmmeter
should show continuity (0 ohms).
(5) Depress the clutch pedal at least 33 mm (1.30
in.) check for continuity between terminals1&2.
There should be no continuity between the terminals
(open circuit).
(6) If ohmmeter readings do not fall within these
ranges, the switch assembly is defective and should
be replaced. If the switch tests ok, wiring is defective.
Refer to Group 8W, Wiring Diagrams and repair
defective wiring.
Fig. 6 Clutch/Brake Pedal Bracket Assembly
1 ± UPSTOP SWITCH
2 ± CLUTCH PEDAL
3 ± INTERLOCK SWITCH
4 ± CONNECTOR
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSIS±CLUTCH INTERLOCK/UPSTOP SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE STARTER
WON'T CRANK
WHEN CLUTCH
PEDAL IS
PRESSED TO THE
FLOORClutch interlock switch does not have
continuity when plunger is depressed 1.25
mm (1.30 in.)Defective switch or open wiring circuit.
Replace switch if necessary.
Interlock switch plunger is not depressed
when clutch pedal is pushed to the floorFloor mat interferes with clutch pedal
movement or clutch pedal bracket is bent.
Problem is related to other components in
the starting circuit.Check other components in the starting
circuit. Refer to Battery/Starting/Charging
System in Group 8.
SPEED CONTROL
DOES NOT
TERMINATE WHEN
CLUTCH PEDAL IS
DEPRESSED BY AT
LEAST 33 mm (1.30
in.)Upstop switch circuit is closed when clutch
pedal is depressed, or harness is shorted.Refer to Upstop Switch Electrical Test in
this group. Repair wiring or replace switch
assembly as necessary.
Other speed control system failure. Refer to Group 8H, Speed Control for
further diagnosis and testing procedures.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Disconnect both battery cables.
(2) Remove battery clamp and remove battery
from vehicle.
(3) Remove battery tray from mount bracket.
(4) Remove bellhousing cap (Fig. 7).
(5) Disconnect clutch cable from transaxle housing
and clutch release lever as shown in (Fig. 7).
(6) Disconnect the clutch cable from the clutch
pedal spacer (Fig. 8).
NOTE: Use care when handling clutch cable
assembly. Improper handling can cause adjuster
mechanism to come apart, making re-installation
difficult.
(7) Carefully guide cable through pedal assembly
bore and remove from vehicle.
INSTALLATION
(1) Insert the clutch pedal end of the cable into
position and connect the cable to the clutch pedal
spacer as shown in (Fig. 8).
(2) Verify adjuster mechanism function as follows:
(a) With slight pressure, pull the clutch release
lever end of the cable to draw the cable taut.(b) Push the clutch cable housing toward the
dash panel (With less than 25 lbs. of effort, the
cable housing should move 30-50mm.). If the cable
Fig. 7 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
PLCLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)

(d) Remove mounting bolt and nut (Fig. 10) and
partially remove air cleaner assembly.
(e) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(4) Remove battery tray from bracket.
(5) Disconnect ground cable at battery tray
bracket.
(6) Disconnect back-up lamp switch connector.
(7) Remove bellhousing cap (Fig. 11).
(8) Disconnect clutch cable from release lever and
remove from transaxle (Fig. 11).
(9) Remove shift cable-to-bracket clips (Fig. 12).
(10) Disconnect shift selector and crossover cable
from levers (Fig. 12). Remove cables and secure out
of the way.
(11) Disconnect the vehicle speed sensor connector
(Fig. 13).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 14).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 14).
(17) Remove bellhousing dust cover (Fig. 14).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 15).(19) Remove starter motor (Fig. 16).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 17).
(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
Fig. 10 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCTFWD
Fig. 11 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
Fig. 12 Shift Cables at Transaxle
1 ± SHIFT CABLES
2 ± CLIPS
3 ± BRACKET
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 18).
(25) Remove transaxle from vehicle (Fig. 18).
(26) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
(1) Inspect clutch release bearing and lever for
excessive wear and replace as necessary.
(2) Install clutch module onto input shaft. Install
transaxle into position.
(3) Install transaxle-to-engine mounting bolts (Fig.
18) and tighten to 95 N´m (70 ft. lbs.) torque.
(4) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (70 ft. lbs.) torque (Fig. 17).
(5) Remove screwjack.
(6) Install NEW drive plate-to-clutch module bolts
and progressively tighten all bolts in a criss-cross
pattern until the modular clutch assembly seats
against the drive plate. Final torque the bolts to 88
N´m (65 ft. lbs.) torque.
(7) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 16).
Fig. 13 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINIONFig. 14 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 15 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
6 - 10 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(8) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(9) Install bellhousing dust cover (Fig. 14).
(10) Install left engine-to-transaxle bending brace
(Fig. 14).(11) Install structural collar (Fig. 14) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(12) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 15).
(13) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(14) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(15) Lower vehicle.
(16) Connect vehicle speed sensor connector (Fig.
13).
(17) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 12).
(18) Connect clutch cable to fork and secure to
transaxle (Fig. 11).
(19) Install bellhousing cap (Fig. 11).
(20) Connect back-up lamp switch connector.
(21) Connect ground strap to transaxle upper
mount bracket.
(22) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
(23) Install the air cleaner/throttle body assy. as
follows:
(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(24) Connect the battery cables.
(25) Road test vehicle and inspect for leaks.
Fig. 16 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 17 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
PLCLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)

cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-
lubrication. During clutch service, apply only a small
amount of grease to the input shaft splines. Excess
grease may be thrown off during operation, contami-
nating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by
driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing
clutch components to become contaminated. Facing of
disc will absorb moisture and bond to the flywheel
and/or, pressure plate, if vehicle is allowed to stand
for some time before use. If this condition occurs,
replacement of clutch assembly may be required.
Drive the vehicle until normal clutch operating tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
CLEANING PRECAUTIONS
Condensation from steam vapors tend to accumu-
late on the internal clutch mechanism when the vehi-
cle is steam cleaned. Facing of disc will absorb
moisture and will bond to flywheel and/or pressure
plate, if vehicle is allowed to stand for some time
before use. If this condition occurs, it may require
replacement of clutch assembly. After cleaning, drive
the vehicle to its normal clutch operating tempera-
ture. This will dry off disc assembly, pressure plate,
and flywheel.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Modular Clutch-to-Drive Plate Bolts..... 88N´m
(65 ft. lbs.)
Transaxle-to-Engine Mounting Bolts...... 95N´m
(70 ft. lbs.)
PLCLUTCH 6 - 13
CLEANING AND INSPECTION (Continued)

COOLING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
COOLING SYSTEM........................1
COOLANT...............................2
COOLANT PERFORMANCE..................2
COOLANT RECOVERY SYSTEM..............3
ENGINE THERMOSTAT.....................3
RADIATOR..............................3
RADIATOR COOLING FAN MODULE...........3
COOLING SYSTEM PRESSURE CAP..........4
RADIATOR HOSES AND CLAMPS............5
WATER PUMP...........................5
AUTOMATIC TRANSMISSION OIL COOLER.....6
ACCESSORY DRIVE BELTS.................6
ENGINE BLOCK HEATER...................6
DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS..............7
ENGINE THERMOSTAT TESTING............14
ACCESSORY DRIVE BELT DIAGNOSIS........14
WATER PUMP DIAGNOSIS................15
COOLING SYSTEM FLOW CHECK...........15
ELECTRIC FAN MOTOR TEST...............15
COOLANT CONCENTRATION TESTING........15
TESTING COOLING SYSTEM FOR LEAKS.....15
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK...............16
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP.......................16
LOW COOLANT LEVEL AERATION...........17
DEAERATION...........................17
TEMPERATURE GAUGE INDICATION.........17
ENGINE BLOCK HEATER..................17
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE.........17COOLANTÐADDING ADDITIONAL...........18
COOLANT LEVELÐSERVICING.............18
COOLING SYSTEMÐDRAINING.............19
COOLING SYSTEMÐREFILLING............19
REMOVAL AND INSTALLATION
WATER PUMP..........................19
WATER PUMP INLET TUBE................20
ENGINE THERMOSTAT....................20
RADIATOR.............................21
RADIATOR DRAINCOCK...................22
COOLING FAN MODULE...................22
COOLANT RECOVERY CONTAINER..........23
ENGINE BLOCK HEATER..................24
ACCESSORY DRIVE BELTS................24
AUTOMATIC BELT TENSIONER & PULLEY....26
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE...................26
CLEANING AND INSPECTION
WATER PUMP..........................28
ACCESSORY DRIVE BELT INSPECTION.......28
COOLING SYSTEM CAP...................28
COOLING SYSTEM CLEANING..............28
RADIATOR FLUSHING....................28
REVERSE FLUSHING.....................29
CHEMICAL CLEANING....................29
ADJUSTMENTS
BELT TENSION..........................29
SPECIFICATIONS
COOLING SYSTEM CAPACITY..............30
TORQUE SPECIFICATIONS.................30
SPECIAL TOOLS
COOLING..............................30
DESCRIPTION AND OPERATION
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, and a water pump to
circulate the coolant. The engine cooling module may
consist of a radiator, electric fan motor, fan, shroud,
coolant reserve system, transmission oil cooler, hoses,clamps, air conditioning condenser and transmission
oil lines.
²When the Engine is cold: The thermostat is
closed and the cooling system has no flow through
the radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open
and the cooling system has flow through the radiator,
engine, heater system, and bypass.
PLCOOLING SYSTEM 7 - 1

Coolant flow circuit for the 2.0L engine is shown in
(Fig. 1).
During any reassembly procedures all pipe fittings
in water jacket, and water box require cleaning and
application of thread sealant for entire length of
threads.
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine block
metal and in the cylinder head area near the exhaust
valves. Then coolant carries this heat to the radiator
where the tube/fin assemblies can give off the heat to
the air.
MopartAntifreeze or the equivalent is recom-
mended for optimum cooling performance and corro-
sion protection when mixed to a freeze point of -37É C
(-35É F).
COOLANT REPLACEMENT
Refer to Group 0, Lubrication and Maintenance for
schedule.
COOLANT PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formula = 1 btu per minute for eachdegree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
²Pure Water (1 btu) boils at 100ÉC (212ÉF) and
freezes at 0ÉC (32ÉF).
²100 Percent Glycol (.7 btu) can cause a hot
engine and detonation and will raise the freeze point
to 22ÉC (-8ÉF).
²50/50 Glycol and Water (0.82 btu) is the recom-
mended combination that provides a freeze point of
-37ÉC (-35ÉF). The radiator, water pump, engine
water jacket, radiator pressure cap, thermostat, tem-
perature gauge, sending unit and heater are all
designed for 50/50 glycol.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of -59ÉC
(-50ÉF).
CAUTION: Richer mixtures cannot be measured
with field equipment which can lead to problems
associated with 100 percent glycol.SELECTION AND ADDITIVES
The use of aluminum cylinder heads, intake mani-
folds, and water pumps requires special corrosion
Fig. 1 Cooling System Operation
1 ± HEATER
2 ± HEAT UP
3 ± COOL DOWN
4 ± PRESSURE CAP
5 ± THERMOSTAT HOUSING6 ± WATER PUMP
7 ± ENGINE
8 ± COOLANT RECOVERY SYSTEM TANK
9 ± RADIATOR
7 - 2 COOLING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

protection. MopartAntifreeze or the equivalent is
recommended for best engine cooling without corro-
sion. When mixed only to a freeze point of -37ÉC
(-35ÉF) to -59ÉC (-50ÉF). If it looses color or becomes
contaminated, drain, flush, and replace with fresh
properly mixed solution.
COOLANT RECOVERY SYSTEM
This system works in conjunction with the radiator
pressure cap to utilize thermal expansion and con-
traction of the coolant to keep the coolant free of
trapped air. The system provides space for expansion
and contraction. Also, the system provides a conve-
nient and safe method for checking and adjusting the
coolant level at atmospheric pressure without remov-
ing the pressure cap. It also provides some reserve
coolant to compensate for minor leaks and evapora-
tion or boiling losses. All vehicles are equipped with
this system (Fig. 2).
Refer to Coolant Level Check, Deaeration, and
Pressure Cap sections for operation and service.
ENGINE THERMOSTAT
The engine thermostat is located on the front of
the engine (radiator side) in the thermostat housing/
engine outlet connector. The thermostat has an air
bleed (vent) located in the flange and a O-ring for
sealing incorporate on it. There is a relief in the ther-
mostat housing/outlet connector for the O-ring.
The engine thermostat is a wax pellet driven,
reverse poppet choke type. It is designed to provide
the fastest warm up possible by preventing leakage
through it and to guarantee a minimum engine oper-
ating temperature of 88 to 93ÉC (192 to 199ÉF). Also,
the thermostat will automatically reach wide open, to
accommodate unrestricted flow to the radiator astemperature of the coolant rises in hot weather to
around 104ÉC (220ÉF). Above this temperature the
coolant temperature is controlled by the radiator, fan,
and ambient temperatureÐnot the thermostat.
A thermostats primary purpose is to maintain
engine temperature in a range that will provide sat-
isfactory engine performance and emission levels
under all expected driving conditions. It also provides
hot water (coolant) for heater performance. It does
this by transferring heat from engine metal and
automatic transmission oil cooler (if equipped) to
coolant, moving this heated coolant to the heater core
and radiator, and then transferring this heat to the
ambient air.
RADIATOR
The radiator is a down-flow type (vertical tubes)
with design features that provide greater strength,
as well as sufficient heat transfer capabilities to keep
the engine coolant within operating temperatures.
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
The radiator has an aluminum core with plastic
tanks. Although stronger than brass, plastic tanks
are subject to damage by impact. Always handle radi-
ator with care.
RADIATOR COOLING FAN MODULE
The radiator cooling fan is a single speed electric
motor driven fan. The fan module includes an electric
motor, fan blade, and a support shroud that is
attached to the radiator (Fig. 3).
Fig. 2 Coolant Recovery System
1 ± RECOVERY HOSE
2 ± ENGINE COOLANT RECOVERY CONTAINER
3 ± PRESSURE CAP
Fig. 3 Radiator Fan
1 ± SCREWS
2 ± LOWER MOUNTS
3 ± FAN MOTOR ELECTRICAL CONNECTOR
PLCOOLING SYSTEM 7 - 3
DESCRIPTION AND OPERATION (Continued)

RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE WORKING ON VEHI-
CLE. RELIEVE PRESSURE BY PLACING A SHOP
TOWEL OVER THE CAP AND WITHOUT PUSHING
DOWN ROTATE IT COUNTERCLOCKWISE TO THE
FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE
SYSTEM STOPS PUSHING OUT COOLANT AND
STEAM AND THE PRESSURE DROPS CONTINUE
SERVICE.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 6).
The hose clamps are removed by using Special Tool
6094 or equivalent constant tension clamp pliers
(Fig. 7) to compress the hose clamp.
A hardened, cracked, swollen or restricted hose
should be replaced. Care should be taken not to dam-
age radiator inlet and outlet when removing hoses.
Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.Make sure hoses and connectors are clean and dry
before installation. Do not lubricate hoses when
installing.
Spring type hose clamps are used in all applica-
tions. If replacement is necessary, replace with the
original Mopartequipment spring type clamp.
WATER PUMP
The water pump has a diecast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the cylinder block and is
driven by the timing belt (Fig. 8). Cylinder block to
water pump sealing is provided by a rubber O-ring.
The water pump is the ªheartº of the cooling sys-
tem. It pumps the coolant through the engine block,
cylinder head, heater core, and radiator.
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 6 Spring Clamp Size Location
1 ± SPRING CLAMP SIZE LOCATION
Fig. 7 Hose Clamp Tool
1 ± HOSE CLAMP TOOL 6094
2 ± HOSE CLAMP
Fig. 8 Water Pump
1 ± CYLINDER BLOCK
2 ± PUMP BODY
PLCOOLING SYSTEM 7 - 5
DESCRIPTION AND OPERATION (Continued)