check engine DODGE NEON 2000 Service Service Manual

STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE.1. BATTERY
DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT
WIRING FAULTY.
3. STARTER RELAY
FAULTY.
4. IGNITION SWITCH
FAULTY.
5. PARK/NEUTRAL
STARTING AND
BACK-UP LAMP
SWITCH (AUTO TRANS)
FAULTY OR MIS-
ADJUSTED.
6. CLUTCH
INTERLOCK/UPSTOP
SWITCH (MAN TRANS)
FAULTY.
7. STARTER SOLENOID
FAULTY.
8. STARTER ASSEMBLY
FAULTY.1. REFER TO GROUP 8A, BATTERY. CHARGE OR REPLACE
BATTERY, IF REQUIRED.
2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. REFER TO IGNITION SWITCH TEST, IN GROUP 8D-
IGNITION SYSTEM OR GROUP 8W-WIRING DIAGRAMS.
REPLACE SWITCH, IF NECESSARY.
5. REFER PARK/NEUTRAL STARTING AND BACK-UP LAMP
SWITCH TEST IN GROUP 21-TRANSAXLE. REPLACE SWITCH,
IF NECESSARY.
6. REFER TO CLUTCH INTERLOCK/UPSTOP SWITCH TEST,
IN GROUP 6-CLUTCH (LOCATED WITHIN THE SWITCH
REMOVAL AND INSTALLATION). REPLACE SWITCH, IF
NECESSARY.
7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.1. BATTERY
DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT
WIRING FAULTY.
3. STARTER ASSEMBLY
FAULTY.
4. ENGINE SEIZED.1. REFER TO GROUP 8A, BATTERY. CHARGE OR REPLACE
BATTERY AS NECESSARY.
2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. REFER TO GROUP 9-ENGINE, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.
2. STARTER ASSEMBLY
FAULTY.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.
2. STARTER RELAY
FAULTY.
3. IGNITION SWITCH
FAULTY.
4. STARTER ASSEMBLY
FAULTY.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. REFER TO IGNITION SWITCH TEST, IN GROUP 8D-
IGNITION SYSTEM. REPLACE SWITCH, IF NECESSARY.
4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
PLSTARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)

IGNITION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
IGNITION SYSTEM........................1
SPARK PLUGS...........................1
SPARK PLUG CABLES.....................1
ELECTRONIC IGNITION COILS...............2
AUTOMATIC SHUTDOWN RELAY.............2
CRANKSHAFT POSITION SENSORÐPCM
INPUT................................3
CAMSHAFT POSITION SENSORÐPCM
INPUT................................4
KNOCK SENSOR..........................5
IGNITION SWITCH........................5
LOCK KEY CYLINDER......................5
IGNITION INTERLOCK.....................6
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE....................6SPARK PLUG CABLE SERVICE..............6
IGNITION COIL...........................6
AUTOMATIC SHUTDOWN RELAY.............6
CAMSHAFT POSITION SENSOR..............6
CRANKSHAFT POSITION SENSOR............8
KNOCK SENSOR..........................8
IGNITION SWITCH........................8
LOCK KEY CYLINDER......................9
IGNITION INTERLOCK....................10
SPECIFICATIONS
VECI LABEL............................10
FIRING ORDERÐ2.0L....................10
TORQUE SPECIFICATION..................11
SPARK PLUG CABLE RESISTANCEÐSOHC....11
SPARK PLUG...........................11
IGNITION COIL..........................11
DESCRIPTION AND OPERATION
IGNITION SYSTEM
DESCRIPTION
The system's three main components are the coil
pack, crankshaft position sensor, and camshaft posi-
tion sensor.
OPERATION
Basic ignition timing is not adjustable.The
Powertrain Control Module (PCM) determines spark
advance. The 2.0L engines use a fixed ignition timing
system. The distributorless electronic ignition system
is referred to as the Direct Ignition System (DIS).
SPARK PLUGS
The 2.0L engines uses resistor spark plugs. For
spark plug identification and specifications, Refer to
the Specifications section at the end of this group.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. Aftercleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the
electrodes (Fig. 1) to the dimensions specified in the
chart at the end of this section by bending the
ground electrode (just above the attachment weld)
with the appropriate tool.
Never apply any force between the electrode or
damage to the center electrode assembly will result.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion and damage.
Tighten spark plugs to 28 N´m (20 ft. lbs.) torque.
SPARK PLUG CABLES
Spark plug cables are sometimes referred to as sec-
ondary ignition wires. The wires transfer electrical
current from the coil pack to individual spark plugs
at each cylinder. The resistor type, nonmetallic spark
plug cables provide suppression of radio frequency
emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil and spark plugs. Terminals should
be fully seated. The nipples and spark plug covers
should be in good condition. Nipples should fit tightly
on the coil. Spark plug boot should completely cover
the spark plug hole in the cylinder head cover. Install
the boot until the terminal snaps over the spark
plug. A snap must be felt to ensure the spark plug
cable terminal engaged the spark plug.
PLIGNITION SYSTEM 8D - 1

IGNITION INTERLOCK
OPERATION
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Off, Run or Start position. In addi-
tion, the operator cannot rotate the key to the lock
position unless the shifter is in the park position. On
vehicles equipped with floor shift refer to the - Tran-
saxle for Automatic Transmission Shifter/Ignition
Interlock.
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
REMOVAL
REMOVE CABLES FROM COIL FIRST.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
(1) Remove the spark plug using a quality socket
with a rubber or foam insert.
(2) Inspect the spark plug condition.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube.
Reconnect to coil.
SPARK PLUG CABLE SERVICE
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
REMOVAL
Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube. The connect theother end to coil pack. Be sure that dual plastic clip
holds the cables off of the valve cover.
IGNITION COIL
The electronic ignition coil pack attaches directly
to the valve cover (Fig. 11).
REMOVAL
(1) Disconnect electrical connector from coil pack
(Fig. 10).
(2) Remove coil pack mounting bolts.
(3) Remove coil pack.
INSTALLATION
(1) Install coil pack on valve cover.
(2) Transfer spark plug cables to new coil pack.
The coil pack towers are numbered with the cylinder
identification. Be sure the ignition cables snap onto
the towers.
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 12). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
CAMSHAFT POSITION SENSOR
The camshaft position sensor is mounted to the
rear of the cylinder head (Fig. 13).
Fig. 10 Electronic Ignition Coil Connector
1 ± COIL
2 ± LOCKING TAB
8D - 6 IGNITION SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

DESCRIPTION AND OPERATION
HEADLAMP SWITCH
The headlamp switch is part of the Multi-Function
Switch. Refer to Group 8J, Turn Signal and Flasher
for the Multi-Function Switch Test, Removal and
Installation procedures.
INSTRUMENT CLUSTER
There are two conventional instrument cluster
assemblies available. The clusters electronically drive
the speedometer, odometer, gauges, and tachometer
(if equipped). Refer to (Fig. 2) and (Fig. 3).
The instrument cluster controls the courtesy
lamps, it receives and sends messages to other mod-
ules via the PCI bus circuit, it controls all the instru-
ment illumination and the chime is also an integral
part of the cluster. The front turn signals are wired
through the cluster and then go to the front lamps.
The reason being that the DRL module is built into
the cluster (if equipped).
All gauges in the electronic clusters are the analog
type gauges. When the ignition switch is moved to
the OFF position, the cluster drives each gauge to its
lowest position. The individual gauges are not servi-
cable and require complete replacement of the cluster
if one or more gauges are inoperable.
One button is used to switch the display from trip
to total mileage. Holding the button when the display
is in the trip mode will reset the trip mileage. This
button is also used to put the cluster in self-diagnos-
tic mode. Refer to Service Procedures, Cluster Self-
Diagnostics in this section. Most of the indicators will
come on briefly for a bulb heck when the ignition is
turned from OFF to ON. All of the LED's are replace-
able.
In the event that the instrument cluster looses
communication with all other modules on the PCI
bus, the cluster will display ªnobusº in the VF dis-
play. The VF display also displays ªDoorº, ªCruiseº,
ªTracº, and odometer trip or total.
If the cluster does not detect voltage on the cour-
tesy lamp circuit, the message ªFUSEº will alternate
with the odometer/trip odometer for 30 seconds after
the ignition is turned on and for 15 seconds after the
vehicle is first moved. The lack of voltage can be due
to the M1 Fused B(+) (IOD) fuse being open, a bad or
missing courtesy lamp bulb, or a circuit problem.
WARNING AND INDICATOR LAMPS
The instrument cluster has warning lamps and
indicators for the following systems:
²Airbag
²Anti-lock Brakes (ABS) if equipped
²Brake warning
²Charging System²Front fog lamps (if equipped)
²High beam indicator
²Low fuel (premium cluster only)
²Low oil pressure
²Malfunction indicator (service engine soon) lamp
²Right and left turn signals
²Seat belt warning
²Security system
²Trac-Off (ABS equipped vehicles only)
The instrument cluster has a Vacuum Fluorescent
(VF) display for the following systems:
²Cruise
²Door (ajar)
²Odometer
²Set (cruise)
²Trac
²Trip
DIAGNOSIS AND TESTING
AIRBAG WARNING SYSTEM
For testing of this system refer to Group 8M, Pas-
sive Restraint Systems.
BRAKE SYSTEM WARNING LAMP TEST
The brake warning lamp illuminates when the
parking brake is applied with ignition switch turned
to the ON position. The same lamp will also illumi-
nate if one of the two service brake systems fail the
when brake pedal is applied.
To test the system:
²As the ignition switch is turned to the start posi-
tion the lamp should light.
²Turn ignition switch to the ON position and
apply the parking brake. The lamp should light.
If lamp fails to light inspect for:
²A burned out lamp
²Loose, corroded or damaged socket
²A damaged circuit board
²A broken or disconnected wire at the switch
²Defective switch
To test the service brake warning system, refer to
Group 5, Brakes, Hydraulic System Control Valves.
INSTRUMENT CLUSTER LAMPS
Every time the vehicle is switched to the START/
RUN position, the cluster goes through a BULB
CHECK. This tests most of the indicator lamps and
Vacuum Fluorescent (VF) displays. If only one lamp
is out, remove the instrument cluster and replace the
defective bulb or Light Emitting Diode (LED). If
some or all of the lamps fail to light, refer to the
proper Body Diagnostics Procedures Manual.
8E - 2 INSTRUMENT PANEL SYSTEMSPL

To diagnose the cluster lamps first place the clus-
ter in self-diagnostic mode. With the ignition switch
in the off position, press the trip odometer reset but-
ton down. Simultaneously turn the ignition key to
the ON position and release the trip reset button. All
the indicator lamps and VF displays should illumi-
nate except for the fog lamp, turn signal, and high
beam select indicators. Refer to (Fig. 2), (Fig. 3), and
the Cluster Identification table.
1 ± FOG LAMP
2 ± BRAKE**
3 ± TRAC OFF**
4 ± ABS**
5 ± SPEEDOMETER
6 ± LEFT/RIGHT TURN SIGNAL
7 ± HIGH BEAM
8 ± TACHOMETER
9 ± OIL PRESSURE**
10 ± SEAT BELT**
11 ± BATTERY**
12 ± AIR BAG**
13 ± SECURITY*
14 ± FUEL FILLER DOOR LOCATOR
15 ± FUEL GAUGE
16 ± LOW FUEL*
17 ± MALFUNCTION INDICATOR LAMP (MIL)**
18 ± TRIP RESET BUTTON
19 ± TRAC**
20 ± ODOMETER**
21 ± DOOR (AJAR)**
22 ± SET CRUISE*
23 ± TRIP**
24 ± CRUISE*
25 ± TEMPERATURE GAUGE
*ILLUMINATE DURING SELF-DIAGNOSTICS
**ILLUMINATE DURING BULB CHECK AND SELF-DIAGNOSTICS
LOW OIL PRESSURE WARNING LAMP TEST
The low oil pressure warning lamp will illuminate
when the ignition switch is turned to the ON position
without engine running. The lamp also illuminates if
the engine oil pressure drops below a safe oil pres-
sure level.To test the system, turn the ignition switch to the
ON position. If the lamp fails to light, inspect for a
broken or disconnected wire at the oil pressure
switch, located at the front of the engine (Fig. 4). If
the wire at the connector checks good, pull the con-
nector loose from the switch and with a jumper wire,
ground the connector to the engine. With the ignition
switch turned to the ON position, check the warning
lamp. If the lamp still fails to light, inspect for a
burned out lamp or disconnected socket in the clus-
ter.
Fig. 2 Base Instrument Cluster Without Tachometer
Fig. 3 Premium Instrument Cluster With Tachometer
1 ± FOG LAMP
2 ± BRAKE**
3 ± TRAC OFF**
4 ± ABS**
5 ± SPEEDOMETER
6 ± LEFT/RIGHT TURN SIGNAL
7 ± HIGH BEAM
8 ± TACHOMETER
9 ± OIL PRESSURE**
10 ± SEAT BELT**
11 ± BATTERY**
12 ± AIR BAG**
13 ± SECURITY*
14 ± FUEL FILLER DOOR LOCATOR
15 ± FUEL GAUGE
16 ± LOW FUEL*
17 ± MALFUNCTION INDICATOR LAMP (MIL)**
18 ± TRIP RESET BUTTON
19 ± TRAC**
20 ± ODOMETER**
21 ± DOOR (AJAR)**
22 ± SET CRUISE*
23 ± TRIP**
24 ± CRUISE*
25 ± TEMPERATURE GAUGE
*ILLUMINATE DURING SELF-DIAGNOSTICS
**ILLUMINATE DURING BULB CHECK AND SELF-DIAGNOSTICS
PLINSTRUMENT PANEL SYSTEMS 8E - 3
DIAGNOSIS AND TESTING (Continued)

MULTIPLE/INDIVIDUAL GAUGES INOPERATIVE
Test speedometer, tachometer and other gauges for
malfunction:
(1) Remove the cluster. Refer to Cluster Removal
and Installation.
(2) Check for ignition voltage at Pin 15 of the clus-
ter wire harness connector (Fig. 5). Check for battery
voltage at Pin 21 of the connector. If no voltage,
repair as necessary.
(3) Check Pin 10 of the connector for continuity to
ground. If no ground, repair as necessary.
(4) If the voltage and ground are OK, and the pins
or the connectors are not distorted, replace the
instrument cluster.
(5) Install cluster. Refer to Instrument Cluster
Removal and Installation in this section.
SERVICE PROCEDURES
INSTRUMENT CLUSTER SELF-DIAGNOSTICS
To put the cluster in self-diagnostics mode press
the trip reset button down and then turn the ignition
to the RUN position simultaneously, then release the
button. The gauges will increment to selected stoops
and all indicators will light with the exception of the
turn signals, high beam, and fog lamp indicators.
The oil lamp will come on when the ignition is
turned ON and the engine is OFF.
REMOVAL AND INSTALLATION
ACCESSORY SWITCH/POWER OUTLET BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 6).
(2) Remove the instrument panel center bezel.
Refer to Instrument Panel Center Bezel Removal and
Installation in this section.
(3) Remove four screws retaining accessory switch/
power outlet bezel (Fig. 7).(4) Disconnect the harness connectors to the fol-
lowing:
²Rear Window Defogger Switch (if equipped)
²Traction Control Switch (if equipped)
²Cigar Lighter/Power Outlet
Fig. 5 Cluster Wire Harness Connector
INSTRUMENT CLUSTER CONNECTOR PIN
CALL-OUT
PIN DESCRIPTION PIN DESCRIPTION
1 REAR FOG
LAMP FEED14 PARK LAMP
SWITCH
OUTPUT
2 PCI BUS 15 FUSED IGNITION
SWITCH
OUTPUT
(RUN-START)
3 COURTESY
LAMPS DRIVER16 DAYTIME
RUNNING
LAMPS
4 FOG LAMP
SWITCH
OUTPUT17 DAYTIME
RUNNING
LAMPS
5 VTSS
INDICATOR
DRIVER18 LEFT TURN
SIGNAL
6 PANEL LAMPS
DIMMER
SIGNAL19 RIGHT TURN
SIGNAL
7 FUEL LEVEL
SENSOR
SIGNAL20 DIMMER
SWITCH LOW
BEAM OUTPUT
8 NOT USED 21 FUSED B+
9 NOT USED 22 RED BRAKE
WARNING
INDICATOR
DRIVER
10 GROUND 23 KEY-IN IGNITION
SWITCH SENSE
11 NOT USED 24 DRIVER DOOR
AJAR SWITCH
SENSE
12 PANEL LAMPS
DRIVER25 SEAT BELT
SWITCH SENSE
13 KEYLESS
ENTRY SIGNAL26 DIMMER
SWITCH HIGH
BEAM OUTPUT
Fig. 4 Oil Pressure Switch
8E - 4 INSTRUMENT PANEL SYSTEMSPL
DIAGNOSIS AND TESTING (Continued)

AUDIO SYSTEM
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION...............1
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES......1
TESTING................................1
BENCH TEST FOR ANTENNA MALFUNCTION...7REMOVAL AND INSTALLATION
CD CHANGER............................7
FRONT DOOR SPEAKER....................8
INSTRUMENT PANEL SPEAKER(S)...........8
MAST and ANTENNA ASSEMBLY.............8
RADIO..................................9
REAR SHELF SPEAKER(S).................10
GENERAL INFORMATION
INTRODUCTION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with the vehicle.
The vehicles are equipped with an Interior (Igni-
tion Off Draw) fuse in the Power Distribution Center
located in the engine compartment. After the Interior
(IOD) fuse or battery has been disconnected the clock
will require resetting. The radio station presets have
a nonvolatile memory and will retain the preset sta-
tions after a battery disconnect.
The available radio options are:
²AM/FM Stereo Cassette w/Clock
²AM/FM/CD
²AM/FM Cassette w/CD Changer Controls and
Display
²CD/4 Disc Changer - In-Dash (used w/Radio CD
Changer Controls)
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION
The radio utilizes a ground wire plugged on to a
blade terminal and is bolted to the radio chassis.
Both connector and terminal should be securely
attached. The engine has two separate ground straps
to suppress ignition noise which may interfere with
radio reception.
²Left engine mount clip on strap
²Engine to shock tower reinforcement
Inductive type spark plug cables in the high ten-
sion circuit of the ignition system complete the inter-
ference suppression. Faulty or deteriorated spark
plug wires should be replaced.
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES
CAUTION: The CD player will only operate between
approximate temperatures of -23ÉC and +65ÉC (-10ÉF
and +145ÉF).
Whenever a radio malfunction occurs;
(1) First check FUSES:
(a) Power Distribution Center (PDC), Interior
lamp fuse, M1 - Radio Memory Feed
(b) Fuse Block:
(I) Fuse 12, Illumination in the fuse block
(II) Fuse 16, Ignition feed in the fuse block
NOTE: The vehicles are shipped with the INTERIOR
LAMP fuse disconnected.
(2) Verify, the radio wire harness are properly con-
nected before starting normal diagnosis and repair
procedures. Refer to Audio Diagnostic Charts and/or
Group 8W, Wiring Diagrams, Radio Section.
TESTING
The antenna has a short cable which connects into
the instrument panel harness. The connection is
made on the right side of the instrument panel.
Antenna performance may be tested by substitut-
ing a known good antenna. It is also possible to
check short or open circuits with an ohmmeter or
continuity light once the antenna cable is discon-
nected from the radio as follows:
(1) Continuity should be present between the
antenna mast and radio end pin of antenna cable
plug (Fig. 1).
(2) No continuity should be observed or a very
high resistance of several megohms between the
ground shell of the connector and radio end pin.
PLAUDIO SYSTEM 8F - 1

TERMINOLOGY
This a list of terms with there definitions used in
the wiring diagrams.
Built-Up-Export....... Vehicles Built For Sale In
Markets Other Than North America
Except-Built-Up-Export . Vehicles Built For Sale In
North America
LHD ................Left Hand Drive Vehicles
RHD ...............Right Hand Drive Vehicles
ATX . . Automatic Transmission-Front Wheel Drive
MTX ....Manual Transmission-Front Wheel Drive
AT ....Automatic Transmission-Rear Wheel Drive
MT......Manual Transmission-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC............Dual Over Head Cam Engine
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located on theengine com-
partment harnessareC100series numbers.
²Connectors located on theinstrument panel
harnessareC200series numbers.
²Connectors located on thebody harnessare
C300series numbers.
²Jumper harness connectorsareC400series
numbers.
²Grounds and ground connectorsare identi-
fied with aªGºand follow the same series number-
ing as the in-line connector.
Component connectors are identified by the compo-
nent name instead of a number. Multiple connectors
on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-90 contains connector/ground location
illustrations. The illustrations contain the connector
name (or number)/ground number and component
identification. Connector/ground location charts in
Section 8W-90 reference the illustration number for
components and connectors.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the Dia-
gram pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
PL8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)

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

ENGINE
TABLE OF CONTENTS
page page
STANDARD SERVICE PROCEDURES........... 1
ENGINE DIAGNOSIS........................ 82.0L SOHC ENGINE....................... 15
STANDARD SERVICE PROCEDURES
TABLE OF CONTENTS
page page
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS........1
ENGINE GASKET SURFACE PREPARATION.....2
CRANKSHAFT DAMPER BOLT ACCESS PLUG . . . 2
ENGINE CORE PLUGS.....................2
ENGINE PERFORMANCE...................3HONING CYLINDER BORES.................3
MEASURING WITH PLASTIGAGE.............4
REPAIR OF DAMAGED OR WORN THREADS....5
HYDROSTATIC LOCKED ENGINE.............5
CHECKING ENGINE OIL LEVEL..............6
ENGINE OIL SERVICE......................7
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANT
MopartBed Plate Sealant is a unique (green-in-
color) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components. The material
cures slowly in the absence of air when torqued
between two metallic surfaces, and will rapidly cure
when heat is applied.
PLENGINE 9 - 1