motor start DODGE NEON 2000 Service Owner's Guide

28 26
2524
T40
14
BR
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
6
SWITCH IGNITION
MOTOR STARTER
ENGINE
BR14 T40
30A
FUSE
9
9
A0
6
RD
CENTER DISTRIBUTION
POWER
1 2
A0
8
RD
BATTERY
S125
BK/GY8 A11
GENERATOR
4C102
M
3 LOCK 0 OFF
2 RUN 1 START
2 HOLD-IN 1 PULL-IN A41
14
YL
A41
14
YL23C103B23
C131
POWERTRAIN
CONTROL
MODULE
K90
20
TN
K90
20
TN
6C101
A1
14
RD
B24C10324
A1
14
RD
A1
14
RD
B(+)
STARTER
RELAY
CONTROL
4
1
2
03
7
1
4 ACC
MOTOR ENGINE
A11
12
BK
BK/GY8 A11
FUSIBLE
LINK
BK/GY8 A11
(8W-10-8)(8W-10-2)
(8W-10-3)
(8W-20-2)
(8W-20-2)
(8W-10-8)
(8W-30-15)
8W - 21 - 2 8W-21 STARTING SYSTEMPL
008W-10PLI02102

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay...........8W-30-9
A/C High Pressure Switch.............8W-30-11
Airbag Control Module................8W-30-4
Automatic Shut Down Relay........8W-30-2, 3, 5
Brake Lamp Switch............8W-30-12, 13, 14
Brake Shift Interlock Solenoid.........8W-30-13
Brake Warning Indicator Switch........8W-30-13
Camshaft Position Sensor..............8W-30-7
Center High Mounted Stop Lamp.......8W-30-14
Clockspring........................8W-30-12
Clutch Interlock Switch..............8W-30-15
Controller Anti-Lock Brake..........8W-30-4, 13
Crankshaft Position Sensor............8W-30-7
Data Link Connector................8W-30-2, 4
Engine Coolant Temperature Sensor.....8W-30-7
Engine Oil Pressure Switch............8W-30-2
Engine Starter Motor Relay...........8W-30-15
Fuel Injector No. 1...................8W-30-5
Fuel Injector No. 2...................8W-30-5
Fuel Injector No. 3...................8W-30-5
Fuel Injector No. 4...................8W-30-5
Fuel Pump Module..................8W-30-10
Fuel Pump Relay...................8W-30-10
Fuel Tank.........................8W-30-10
Fuse 6 (FB)........................8W-30-13
Fuse 7 (FB)........................8W-30-13
Fuse 10 (FB).....................8W-30-9, 10
Fuse 11 (FB).....................8W-30-9, 10
Fuse 21 (PDC)..................8W-30-2, 4, 10
Fuse 23 (PDC)......................8W-30-13
Fuse Block....................8W-30-9, 10, 13
G101........................8W-30-3, 12, 15Component Page
G102.......................8W-30-2, 4, 13, 15
G201.............................8W-30-12
G303.............................8W-30-10
Generator.........................8W-30-11
Idle Air Control Motor................8W-30-8
Ignition Coil........................8W-30-5
Inlet Air Temperature Sensor...........8W-30-6
Instrument Cluster................8W-30-4, 10
Knock Sensor.......................8W-30-6
Leak Detection Pump.................8W-30-9
Left Tail/Stop Lamp.................8W-30-14
Manifold Absolute Pressure Sensor......8W-30-6
Multi-Function Switch...............8W-30-14
Noise Suppressor....................8W-30-5
Oxygen Sensor 1/1 Upstream...........8W-30-3
Oxygen Sensor 1/2 Downstream.........8W-30-3
Park/Neutral Position Switch..........8W-30-15
Power Distribution Center......8W-30-2, 4, 10, 13
Power Steering Pressure Switch........8W-30-15
Powertrain Control Module.....8W-30-2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, 13, 15
Proportional Evap/Purge Solenoid.......8W-30-15
Radiator Fan Relay...................8W-30-9
Remote Keyless Entry Module..........8W-30-4
Right Tail/Stop Lamp................8W-30-14
Sentry Key Immobilizer Module.........8W-30-4
Throttle Position Sensor...............8W-30-6
Torque Converter Clutch Solenoid.......8W-30-9
Vehicle Speed Control Servo........8W-30-12, 13
Vehicle Speed Control Switch..........8W-30-12
Vehicle Speed Sensor.................8W-30-8
PL8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1

C26831C1
MODULE CONTROL
POWERTRAIN70C2
1
2
PROPORTIONAL
EVAP/
PURGE
SOLENOID
K108
20
DB
K52
20
PK/BK
24
28
STARTER
MOTOR
(IN PDC)
6C101
K90
20
TN
K90
20
TN
C12376C2
13
2
C1017
Z1
18
BK
Z1
18
BK
SWITCH INTERLOCK
CLUTCH
2
SWITCH
POSITION
NEUTRAL
PARK/
5C108
MTX ATX
K119
18
LG/BK
K119
20
LG/BKT141
20
YL/RDT41
18
BR/YL
T41
18
BR/YL
G101 S112ENGINE
RELAY
EVAPORATIVE
EMISSION
SOLENOID
SENSE
POWER
STEERING
PRESSURE
SWITCH
SENSEENGINE
STARTER
MOTOR
CLUTCH
SWITCHCLUTCH
INTERLOCK
SWITCH
SENSEPARK/
NEUTRAL
POSITION
SWITCH
SENSE
MTX ATX
1
POWER
STEERING
PRESSURE
SWITCH
WT20 K10
45C2
2
S107
G102
BK/TN20 Z12
BK/TN18 Z12
(MTX)
RELAY
CONTROL PROPORTIONAL
EVAP/
PURGE
SOLENOID
CONTROL(8W-21-2)
(8W-51-2)
(8W-15-3)
(8W-15-3) (8W-15-4)
(8W-15-4)
PL8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15
PLI03015008W-10

CAV CIRCUIT FUNCTION
1 K59 20VT IDLE AIR CONTROL NO. 4 DRIVER
2 K40 20BR/WT
3 K60 20YL/BK
4 K39 20GY/RD
CAV CIRCUIT FUNCTION
1 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
2 AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
14
31
MOTOR CONTROLIDLE AIR
IGNITION COIL
IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR CONTROL NO. 2 DRIVER
IDLE AIR CONTROL NO. 1 DRIVER
BLACK BLACK
- -10
CAV CIRCUIT FUNCTION
1
2FUSED B(+)
4 3
7 IGNITION SWITCH OUTPUT (RUN-ACC)
8
FUSED B(+) 6KEY-IN IGNITION SWITCH SENSE 5
A1 14RD
G26 22LB
A31 14BK/WT
A2 12PK/BK
9
IGNITION
SWITCH
5
10 61
A21 14DB
IGNITION SWITCH OUTPUT (ST-RUN)
F30 16RD
IGNITION SWITCH OUTPUT (RUN-ACC)
F1 16DB
A41 14YL
IGNITION SWITCH OUTPUT (START)
A22 12BK/OR
IGNITION SWITCH OUTPUT (RUN) Z1 18BKGROUND
2
1
SWITCH HOOD AJAR
HOOD AJAR SWITCH SENSE
G70 18BR/TNFUNCTION
CAV CIRCUIT
1
2
FUSED B(+) A142 18DG/OR BLACK
BLACK
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTSPL
008W-10PLI08026

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.
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment3
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel7, 8
G202 Lower Center
of Instrument
Panel7, 8
G203 Lower Center
of Instrument
Panel7, 8
G204 Lower Center
of Instrument
Panel7, 8
G301 Inner Left
Rear Quarter
Panel11
G302 Inner Right
Rear Quarter
Panel12
G303 Inner Left
Rear Quarter
Panel11
G304 At Decklid 17
Generator BK Left Rear of
Engine5
Glove Box
Lamp/SwitchBK Rear of
Lamp/Switch6, 7
Headlamp
Leveling
Switch
(Built-Up-
Export)BK Center of
Instrument
Panel7
High Note
HornBK Right Inner
Fender1
Hood Ajar
SwitchBK Right Side of
Engine
CompartmentN/SConnector
Name/NumberColor Location Fig.
Idle Air Control
MotorBK On Throttle
Body2
Ignition Coil BK Top of Valve
Cover5
Ignition Switch BK Rear of
Switch6
Inlet Air
Temperature
SensorBK Left Front of
Engine
Compartment2
Instrument
ClusterBK Left Side of
Instrument
Panel6
Knock Sensor BK Left Front of
Engine4
Leak
Detection
Pump (Except
Built-Up-
Export)BK Left Rear of
Vehicle13
Left Back-Up
LampBK At Lamp 11
Left City Lamp
(Built-Up-
Export)BK At Lamp N/S
Left Front
Door SpeakerBK At Drivers
Door14
Left Front Fog
LampBK At Lamp N/S
Left Front Side
Marker Lamp
(Except
Built-Up-
Export)NAT At Lamp N/S
Left Front Turn
Signal Lamp
(Built-Up-
Export)NAT At Lamp 2
Left Front
Wheel Speed
SensorBK At Left Front
Wheel
Opening2
Left Headlamp BK At Lamp 2
Left Headlamp
Leveling Motor
(Built-Up-
Export)GY Rear of Left
HeadlampN/S
Left
Instrument
Panel SpeakerBK At Speaker 6
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
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)

²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 5). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. Thefollowing is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 5). In addition, suspect areas can be
checked by placing plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the scale pro-
vided on the package. Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications.Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
Fig. 6 Clearance Measurement
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSIS
TABLE OF CONTENTS
page page
DIAGNOSIS AND TESTING
GENERAL INFORMATION...................8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS......8
CYLINDER COMPRESSION PRESSURE TEST . . . 8
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.........................9LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS............................9
ENGINE OIL LEAK INSPECTION..............9
ENGINE DIAGNOSISÐPERFORMANCE........11
ENGINE DIAGNOSISÐMECHANICAL.........12
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System, for the fuel system diag-
nosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
(7) Repeat the previous step for all remaining cyl-
inders.
(8) Compression should not be less than (689 kPa)
100 psi and not vary more than 25 percent from cyl-
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
9 - 8 ENGINEPL

(2) Install intake manifold to lower support
bracket bolts (Fig. 31). Tighten bolts to 11 N´m (95
in. lbs.).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect Manifold Absolute Pressure (MAP)
Sensor wiring connector (Fig. 29).(7) Connect knock sensor connector, and wiring at
starter.
(8) Install inlet air duct to intake manifold and
throttle body. Tighten clamp to 3 N´m (30 in. lbs.).
(9) Connect negative cable to battery.
(10) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
Fig. 29 MAP Sensor
Fig. 30 Knock Sensor
1 ± KNOCK SENSOR
2 ± STARTER MOTOR
Fig. 31 Intake Manifold Lower Supports
1 ± BOLT
2 ± BRACKET
3 ± BRACKET
4 ± BOLT
Fig. 32 Intake Manifold Tightening Sequence
PL2.0L SOHC ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)