starter motor DODGE NEON 2000 Service Owner's Guide

(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)

1 second. Therefore, battery voltage is not supplied to
the fuel pump, ignition coil, fuel injectors and heated
oxygen sensors.
ENGINE START-UP MODE
This is an OPEN LOOP mode. If the vehicle is in
park or neutral (automatic transaxles) or the clutch
pedal is depressed (manual transaxles) the ignition
switch energizes the starter relay. The following
actions occur when the starter motor is engaged.
²If the PCM receives the camshaft position sensor
and crankshaft position sensor signals, it energizes
the Auto Shutdown (ASD) relay and fuel pump relay.
If the PCM does not receive both signals within
approximately one second, it will not energize the
ASD relay and fuel pump relay. The ASD and fuel
pump relays supply battery voltage to the fuel pump,
fuel injectors, ignition coil and heated oxygen sen-
sors.
²The PCM energizes the injectors (on the 69É
degree falling edge) for a calculated pulse width until
it determines crankshaft position from the camshaft
position sensor and crankshaft position sensor sig-
nals. The PCM determines crankshaft position within
1 engine revolution.
²After determining crankshaft position, the PCM
begins energizing the injectors in sequence. It adjusts
injector pulse width and controls injector synchroni-
zation by turning the individual ground paths to the
injectors On and Off.
²When the engine idles within664 RPM of its
target RPM, the PCM compares current MAP sensor
value with the atmospheric pressure value received
during the Ignition Switch On (zero RPM) mode. If
the PCM does not detect a minimum difference
between the two values, it sets a MAP diagnostic
trouble code into memory.
Once the ASD and fuel pump relays have been
energized, the PCM determines injector pulse width
based on the following:
²Battery voltage
²Engine coolant temperature
²Engine RPM
²Intake air temperature (IAT)
²Throttle position
²The number of engine revolutions since cranking
was initiated.
During Start-up the PCM maintains ignition tim-
ing at 9É BTDC.
ENGINE WARM-UP MODE
This is an OPEN LOOP mode. The following inputs
are received by the PCM:
²Engine coolant temperature
²Manifold Absolute Pressure (MAP)
²Intake air temperature (IAT)²Crankshaft position (engine speed)
²Camshaft position
²Knock sensor
²Throttle position
²A/C switch
²Battery voltage
²Power steering pressure switch
²Vehicle speed
²Speed control
²O2 sensors
²All diagnostics
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts ignition timing and engine idle
speed. Engine idle speed is adjusted through the idle
air control motor.
CRUISE OR IDLE MODE
When the engine is at operating temperature this
is a CLOSED LOOP mode. During cruising or idle
the following inputs are received by the PCM:
²Intake air temperature
²Engine coolant temperature
²Manifold absolute pressure
²Crankshaft position (engine speed)
²Camshaft position
²Knock sensor
²Throttle position
²Exhaust gas oxygen content
²A/C control positions
²Power steering pressure switch
²Battery voltage
²Vehicle speed
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts engine idle speed and ignition
timing. The PCM adjusts the air/fuel ratio according
to the oxygen content in the exhaust gas (measured
by the upstream and downstream heated oxygen sen-
sor).
The PCM monitors for engine misfire. During
active misfire and depending on the severity, the
PCM either continuously illuminates or flashes the
malfunction indicator lamp (Check Engine light on
instrument panel). Also, the PCM stores an engine
misfire DTC in memory.
The PCM performs several diagnostic routines.
They include:
²Oxygen sensor monitor
²Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
²Fuel system monitor
²EGR monitor
²Purge system monitor
PLFUEL SYSTEM 14 - 23
DESCRIPTION AND OPERATION (Continued)

²All inputs monitored for proper voltage range.
²All monitored components (refer to the Emission
section for On-Board Diagnostics).
The PCM compares the upstream and downstream
heated oxygen sensor inputs to measure catalytic
convertor efficiency. If the catalyst efficiency drops
below the minimum acceptable percentage, the PCM
stores a diagnostic trouble code in memory.
During certain idle conditions, the PCM may enter
a variable idle speed strategy. During variable idle
speed strategy the PCM adjusts engine speed based
on the following inputs.
²A/C sense
²Battery voltage
²Battery temperature
²Engine coolant temperature
²Engine run time
²Power steering pressure switch
²Vehicle mileage
ACCELERATION MODE
This is a CLOSED LOOP mode. The PCM recog-
nizes an abrupt increase in Throttle Position sensor
output voltage or MAP sensor output voltage as a
demand for increased engine output and vehicle
acceleration. The PCM increases injector pulse width
in response to increased fuel demand.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera-
tion the following inputs are received by the PCM:
²A/C pressure transducer
²A/C sense
²Battery voltage
²Intake air temperature
²Engine coolant temperature
²Crankshaft position (engine speed)
²Exhaust gas oxygen content (upstream heated
oxygen sensor)
²Knock sensor
²Manifold absolute pressure
²Power steering pressure switch
²Throttle position
²IAC motor control changes in response to MAP
sensor feedback.
The PCM may receive a closed throttle input from
the Throttle Position Sensor (TPS) when it senses an
abrupt decrease in manifold pressure. This indicates
a hard deceleration. In response, the PCM may
momentarily turn off the injectors. This helps
improve fuel economy, emissions and engine braking.
If decel fuel shutoff is detected, downstream oxy-
gen sensor diagnostics is performed.WIDE-OPEN-THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the PCM:
²Intake air temperature
²Engine coolant temperature
²Engine speed
²Knock sensor
²Manifold absolute pressure
²Throttle position
When the PCM senses a wide-open-throttle condi-
tion through the Throttle Position Sensor (TPS) it de-
energizes the A/C compressor clutch relay. This
disables the air conditioning system.
The PCM does not monitor the heated oxygen sen-
sor inputs during wide-open-throttle operation except
for downstream heated oxygen sensor and both
shorted diagnostics. The PCM adjusts injector pulse
width to supply a predetermined amount of addi-
tional fuel.
IGNITION SWITCH OFF MODE
When the operator turns the ignition switch to the
OFF position, the following occurs:
²All outputs are turned off, unless 02 Heater
Monitor test is being run. Refer to the Emission sec-
tion for On-Board Diagnostics.
²No inputs are monitored except for the heated
oxygen sensors. The PCM monitors the heating ele-
ments in the oxygen sensors and then shuts down.
SYSTEM DIAGNOSIS
OPERATION
The PCM can test many of its own input and out-
put circuits. If the PCM senses a fault in a major
system, the PCM stores a Diagnostic Trouble Code
(DTC) in memory.
For DTC information see On-Board Diagnostics.
POWER DISTRIBUTION CENTER
The Power Distribution Center (PDC) is located
next to the battery (Fig. 1). The PDC contains the
starter relay, radiator fan relay, A/C compressor
clutch relay, auto shutdown relay, fuel pump relay
and several fuses.
POWERTRAIN CONTROL MODULE
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 2). The
PCM receives input signals from various switches
and sensors that are referred to as PCM Inputs.
Based on these inputs, the PCM adjusts various
engine and vehicle operations through devices that
are referred to as PCM Outputs.
PCM Inputs:
14 - 24 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

(11) Disconnect the vehicle speed sensor connector
(Fig. 39).
(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. 40).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 40).
(17) Remove bellhousing dust cover (Fig. 40).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 41).
(19) Remove starter motor (Fig. 42).
(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. 43).
Fig. 39 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINION
Fig. 40 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 41 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
PLTRANSAXLE 21 - 15
REMOVAL AND INSTALLATION (Continued)

(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 44).(25) Remove transaxle from vehicle (Fig. 44).
(26) If installing a new or replacement transaxle,
remove the upper mount as shown in (Fig. 45), trans-
fer to the replacement unit and torque all bolts to 68
N´m (50 ft. lbs.) torque.
INSTALLATION
(1) Install clutch module onto input shaft. Install
transaxle into position.
(2) Install transaxle-to-engine mounting bolts (Fig.
44) and tighten to 95 N´m (70 ft. lbs.) torque.
(3) 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 (80 ft. lbs.) torque (Fig. 43).
(4) Remove screwjack.
(5) Install drive plate-to-clutch module bolts and
torque to 88 N´m (65 ft. lbs.) torque.
(6) 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. 42).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 40).
(9) Install left engine-to-transaxle bending brace
(Fig. 40).
(10) Install structural collar (Fig. 40) 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.
(11) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 41).
(12) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(13) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(14) Lower vehicle.
(15) Connect vehicle speed sensor connector (Fig.
39).
(16) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 38).
(17) Connect clutch cable to fork and secure to
transaxle (Fig. 37).
(18) Install bellhousing cap (Fig. 37).
(19) Connect back-up lamp switch connector.
(20) Connect ground strap to transaxle upper
mount bracket.
(21) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
Fig. 42 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 43 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 16 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

(14) Remove structural collar (Fig. 51).
(15) Remove the left engine-to-transaxle lateral
bending brace (Fig. 51).
(16) Remove bellhousing dust cover (Fig. 51).
(17) Remove starter motor (Fig. 52).
(18) Remove drive plate to converter bolts (Fig.
54).
(19) Support engine at oil pan with screw jack and
wood block.
(20) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 53).
(21) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
(22) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 54).
(23) Remove transaxle from vehicle (Fig. 54).
(24) Remove torque converter from front pump.
(25) If installing a new or replacement transaxle,
remove the upper mount and bracket as shown in
(Fig. 55), and transfer to the replacement unit and
torque all bolts to 68 N´m (50 ft. lbs.) torque.
Fig. 51 Left Lateral Bending Brace and Structural
Collar
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 52 Starter Motor Removal/Installation
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 53 Transaxle Upper Mount and Bracket
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
21 - 86 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install torque converter into front pump.
Rotate converter until the hub fully engages front
pump gear lugs.
(2) Install transaxle-to-engine mounting bolts (Fig.
54) and tighten to 95 N´m (70 ft. lbs.) torque.
(3) 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 (80 ft. lbs.) torque (Fig. 53).
(4) Remove screwjack.
(5) Install converter-to-drive plate bolts and torque
to 88 N´m (65 ft. lbs.) torque.
(6) 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. 52).
(7) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(8) Install bellhousing dust cover (Fig. 51).
(9) Install left engine-to-transaxle bending brace
(Fig. 51).
(10) Install structural collar (Fig. 51) 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.
Fig. 54 Transaxle Removal/Installation
1 ± CLIP
2 ± BOLT (3)3 ± TRANSAXLE
4 ± CONVERTER BOLT (4)
Fig. 55 Transaxle Upper Mount and Bracket
1 ± MOUNT
2 ± TRANSAXLE
PLTRANSAXLE 21 - 87
REMOVAL AND INSTALLATION (Continued)