air conditioning DODGE NEON 2000 Service Repair Manual

GROUP TAB LOCATORINIntroductionINaIntroduction0Lubrication and Maintenance2Suspension3Differential and Driveline5Brakes6Clutch7Cooling8ABattery8BStarting8CCharging System8DIgnition System8EInstrument Panel and Systems8EaInstrument Panel and Systems8FAudio System8GHorns8HVehicle Speed Control System8JTurn Signal and Flashers8KWindshield Wipers and Washers8LLamps8LaLamps8MRestraint System8NElectrically Heated Systems8OPower Distribution Systems8PPower Door Locks8QImmobilizer System8SPower Windows8TPower Mirrors8TaPower Mirrors8UChime Warning/Reminder System8WWiring Diagrams - LHD and RHD9Engine11Exhaust System13Frame and Bumpers14Fuel System19Steering21Transaxle22Tires and Wheels23Body24Heating and Air Conditioning24aHeating and Air Conditioning25Emission Control Systems

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

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)

AUTOMATIC TRANSMISSION OIL COOLER
Oil coolers are internal oil to coolant type, mounted
in the radiator lower tank (Fig. 9). Rubber oil lines
feed the oil cooler and the automatic transmission.
Use only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses
are recommended. Tighten Oil Cooler Hose Clamps
to 2 N´m (18 in. lbs.).
ACCESSORY DRIVE BELTS
The accessory drive consist of two Poly-V type
drive belts (Fig. 10). One belt drives the generator,
the other drives the power steering pump and air
conditioning compressor (if equipped). The power
steering/air conditioning belt is tensioned by an auto-
matically controlled belt tensioner. The generator
belt is manually tensioned using an adjusting bolt
and a locking nut.
ENGINE BLOCK HEATER
The heater is mounted in a core hole (in place of a
core hole plug) in the engine block, with the heating
element immersed in coolant (Fig. 11). The engine
block heater is available as an optional accessory.
The heater is operated by ordinary house current
(110 Volt A. C.) through a power cord and connector
behind the radiator grille.
When in operation, the engine block heater can
provide easier engine starting and faster warm-up,
when vehicle is operated in areas having extremely
low temperatures.CAUTION: The power cord must be secured in its
retainer clips, and not positioned so it could con-
tact linkages or exhaust manifolds and become
damaged.
Fig. 9 Automatic Transmission Oil Cooler
1 ± CLAMPS
2 ± HOSES
Fig. 10 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
Fig. 11 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
7 - 6 COOLING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
TEMPERATURE GAUGE READS
LOW1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open engine thermostat?1. Refer to On Board Diagnostic in
Group 25. Replace thermostat, if
necessary. If a (DTC) has not been
set, the problem may be with the
temperature gauge.
2. Is the temperature gauge (if
equipped) connected to the
temperature gauge coolant sensor
on the engine?2. Check the connector at the
engine coolant sensor. Refer to
Group 8E. Repair as necessary.
3. Is the temperature gauge (if
equipped) operating OK?3. Check Gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low during cold
ambient temperature, accompanied
by poor heater performance.4. Check coolant level in the coolant
recovery/reserve container and the
radiator. Inspect the system for
leaks. Repair as necessary. Refer to
WARNINGS in this section before
removing pressure cap.
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM.1. Trailer being towed, a steep hill
being climbed, vehicle being
operated in slow moving traffic, or
engine idling during high ambient
(outside) temperatures with air
conditioning on. High altitudes
Could aggravate these conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and drive the vehicle
without any of the previous
conditions. Observe the temperature
gauge the gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause of the
overheating and repair. Refer to
POSSIBLE CAUSES in this section.
2. Is temperature gauge (if
equipped) reading correctly?2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Is temperature warning lamp (if
equipped) illuminating
unnecessarily?3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in recovery/reserve
container and radiator?4. Check for coolant leaks and
repair as necessary. Refer to
Checking Cooling System for Leaks
in this section.
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.5. Tighten cap.
PLCOOLING SYSTEM 7 - 7

CONDITION POSSIBLE CAUSE CORRECTION
16. Electric cooling fan not
operating properly.16. Check electric fan operation and
repair as necessary.
17. Cylinder head gasket leaking. 17. Check cylinder head gasket for
leaks. Refer to testing cooling
system for leaks. For repairs, refer
to Group 9, Engine.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning and repair as
necessary.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)1. The gauge may cycle up and
down. This is due to the cycling of
the electric radiator fan.1. A normal condition. No correction
is necessary. If gauge cycling is
going into the hot zone, check
electric fan operation and repair as
necessary. Refer to procedure in
this section.
2. During cold weather operation
with the heater blower in the high
position, the gauge reading may
drop slightly.2. A normal condition. No correction
is necessary.
3, Temperature gauge or engine
mounted gauge sensor is defective
or shorted.3. Check operation of gauge and
repair as necessary. Refer to Group
8E, Instrument Panel and Gauges.
4. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running).4. A normal condition. No correction
is necessary. The gauge should
return to normal range after vehicle
is driven.
5. Gauge reading high after
restarting a warmed-up (hot)
engine.5. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
6. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).6. Check and correct coolant leaks.
Refer to Testing Cooling System For
Leaks in the section.
7. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system. This will cause
thermostat to open late.7. (a) Check for cylinder head
gasket leaks with a commercially
available Block Leak Tester. Repair
as necessary.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from exhaust system. Repair as
necessary.
8. Water pump impeller loose on
shaft.8. Check water pump and replace
as necessary. Refer to Water Pump
in this section.
9. Loose drive belt (water pump
slipping).9. Check drive belt and correct as
necessary.
PLCOOLING SYSTEM 7 - 9
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
ELECTRIC RADIATOR FAN WILL
NOT OPERATE. GAUGE READING
HIGH OR HOT1. Fan motor defective. 1. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
2. Fan relay, powertrain control
module (PCM) or engine coolant
temperature sensor defective.2. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
3. Blown fuse in power distribution
center (PDC).3. Determine reason for blown fuse
and repair as necessary.
NOISY FAN 1. Fan blade loose. 1. Replace fan blade assembly.
Refer to Cooling System Fan in this
section.
2. Fan blade striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.3. Remove obstructions and/or
clean debris from radiator and/or
A/C condenser.
4. Electric fan motor defective. 4. Refer to procedure in this section.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)1. Radiator and/or air conditioning
condenser is restricted, obstructed
or dirty.1. Remove restriction and/or clean
as necessary.
2. Electric radiator fan not operating
when A/C is on.2. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperature due to engine
overheating may also transfer heat
to A/C components.3. Correct overheating condition.
Refer to this section.
PLCOOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)

(3) Remove thermostat/engine outlet connector
bolts (Fig. 22).
(4) Remove thermostat and O-ring assembly.
INSTALLATION
(1) Clean all sealing surfaces.
(2) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align vent with
notch in cylinder head.
(3) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.).
(4) Install upper radiator hose.
(5) Connect the coolant recovery/reserve system
hose.
(6) Refill cooling system. Refer to procedure in this
section.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to procedure in
this section.
(3) Remove upper radiator hose from the radiator.
(4) Disconnect and cap automatic transmission
hoses, if equipped.(5) Disconnect cooling fan motor electrical connec-
tor.
(6) Remove cooling fan module retaining screws,
located on the top of the shroud (Fig. 23). Lift shroud
up and out of bottom shroud attachment clips sepa-
rating shroud from radiator.
(7) Remove the lower radiator hose.
(8) Remove upper radiator isolator bracket mount-
ing screws (Fig. 24). Disconnect the engine block
heater wire, if equipped.
(9) Remove the air conditioning condenser attach-
ing screws located at the front of the radiator, if
equipped (Fig. 25), then lean condenser forward.
NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.
Fig. 22 Thermostat/Engine Outlet Connector
1 ± PRESSURE CAP
2 ± THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
3 ± THERMOSTAT
4 ± O-RING
5 ± VENT FACING UP
Fig. 23 Fan Module Mounting
1 ± SCREWS
2 ± LOWER MOUNTS
3 ± FAN MOTOR ELECTRICAL CONNECTOR
Fig. 24 Radiator Mounting
1 ± UPPER RADIATOR HOSE
2 ± UPPER RADIATOR MOUNTS
PLCOOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)

(10) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Slide radiator down into position behind radia-
tor support (yoke).
(2) Attach air conditioning condenser to radiator, if
equipped (Fig. 25), with four mounting screws.
Tighten screws to 5.4 N´m (50 in. lbs.). Then seat the
radiator assembly lower rubber isolators into the
mounting holes provided in the lower crossmember.
(3) Install and tighten radiator isolator mounting
bracket screws to 10 N´m (90 in. lbs.) (Fig. 24). The
radiator should have clearance to move up, approxi-
mately 5±8 mm (0.20±0.31 in.) after assembled.
(4) Install lower radiator hose. Align the hose and
position the clamp so it will not interfere with engine
components.
(5) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 2 N´m (18 in. lbs.).
(6) Slide fan module down into clip(s) on lower
radiator flange (Fig. 23). Install retaining screws and
tighten to 7.5 N´m (65 in. lbs.).
(7) Connect the cooling fan motor electrical connec-
tor.
(8) Install upper radiator hose. Align the hose and
position the clamp so they will not interfere with the
engine or the hood.
(9) Connect negative cable to battery.
(10) Fill cooling system with coolant. Refer to pro-
cedure in this section.
(11) Operate engine until it reaches normal operat-
ing temperature. Check cooling system and auto-
matic transmission for correct fluid levels.
RADIATOR DRAINCOCK
REMOVAL
(1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 26) from
the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening.
(2) Tighten the draincock stem by turning clock-
wise to 2.0-2.7 N´m (18-25 in. lbs.).
COOLING FAN MODULE
All models use a single speed electric motor driven
cooling system fan. The fan module includes a motor,
fan blade, and support shroud. The module is fas-
tened to the radiator by screws.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system below upper radiator hose
level. Refer to procedure in this section.
(3) Remove upper radiator hose from radiator (Fig.
27).
(4) Disconnect fan module electrical connector.
(5) Remove fan module screws from radiator (Fig.
28).
(6) Lift fan shroud up and out of lower shroud
attachment clips.
(7) Refer to Disassembly and Assembly in this sec-
tion for fan module sub-component service proce-
dures.
Fig. 25 A/C Condenser to Radiator Mounting Screws
1 ± AIR CONDITIONING CONDENSER TO RADIATOR
MOUNTING SCREWS
2 ± LOWER ISOLATOR MOUNTS
Fig. 26 Draincock
1 ± DRAIN COCK BODY
2 ± DRAIN COCK HOUSING
7 - 22 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(2) Connect recovery hose to water outlet connec-
tor/thermostat housing (Fig. 29).
(3) Fill container to proper level. Refer to Cooling
System Refilling in this section.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Draining in this section for
procedure.
(2) Detach power cord plug from heater (Fig. 31).
(3) Loosen screw in center of heater. Remove
heater assembly (Fig. 31).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward (Fig. 31).
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Connect power cord to block heater (Fig. 31).
(5) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks.
ACCESSORY DRIVE BELTS
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
REMOVAL
(1) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be removed from
power steering pump pulley. Gently, release spring
tension on tensioner.
(2) Remove belt (Fig. 34).
INSTALLATION
(1) Install belt (Fig. 34) over all pulleys except for
the power steering pump pulley.
(2) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be installed onto
power steering pulley. Release spring tension onto
belt.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 35). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
Fig. 31 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
Fig. 32 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
7 - 24 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)