maintenance DODGE NEON 2004 2.G User Guide

Malfunction Indicator light to illuminate. The manufac-
turer recommends that you try a different brand of
unleaded gasoline having lower sulfur to determine if the
problem is fuel related prior to returning your vehicle to
an authorized dealer for service.
CAUTION!
If the Check Engine or Service Engine Soon light is
flashing, immediate service is required. See the On
Board Diagnostics paragraph in the Maintenance
section of this manual.
Materials Added to Fuel
All gasoline sold in the United States is required to
contain effective detergent additives. Use of additional
detergents or other additives is not needed under normal
conditions and would result in unnecessary cost. There-
fore you should not have to add anything to the fuel.
Fuel System Cautions
CAUTION!
Follow these guidelines to maintain your vehicle's
performance:
²The use of leaded gas is prohibited by Federal law.
Using leaded gasoline can impair engine performance,
damage the emission control system, and could result
in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²The use of fuel additives which are now being sold as
octane enhancers is not recommended. Most of these
products contain high concentrations of methanol.
Fuel system damage or vehicle performance problems
144 STARTING AND OPERATING

TRAILER TOWING
In this section you will find safety tips and information
on limits to the type of towing you can reasonably do
with your vehicle. Before towing a trailer carefully re-
view this information to tow your load as efficiently and
safely as possible.
To maintain warranty coverage, follow the requirements
and recommendations in this manual concerning ve-
hicles used for trailer towing.
Perform maintenance services as prescribed in the main-
tenance schedules manual. When your vehicle is used for
trailer towing, never exceed the gross axle weight rating
(GAWR) by the addition of:
²The tongue weight of the trailer.
²The weight of any other type of cargo or equipment
put in or on your vehicle.
²Remember that everything put in or on the trailer adds
to the load on your vehicle.
Warranty Requirements
The Manufacturer's Passenger Vehicle Warranty will
apply to vehicles used to tow trailers for non-commercial
use. However the following conditions must be met:
²The maximum trailer load for vehicles with the Stan-
dard 2.0L Engine and manual tranaxles is 1,500 lbs
(680 kg).
²The maximum trailer load for vehicles with the Stan-
dard 2.0L Engine and automatic transaxles is 1,000 lbs
(454 kg).
²Trailer towing is not recommended for vehicles with
the optional 2.0L Magnum Engine (R/T) and manual
transaxle.
²If using a manual transaxle vehicle for trailer towing,
all starts must be in FIRST gear to avoid excessive
clutch slippage.
²The maximum frontal area of the trailer cannot exceed
20 square feet (1.86 square meters).
²The trailer tongue load must be considered as part of
the combined weight of occupants and cargo, and
should never exceed the weight referenced on the Tire
148 STARTING AND OPERATING

CAUTION!
Driving with a hot cooling system could damage
your vehicle. If temperature gauge reads ªHº, pull
over and stop the vehicle. Idle the vehicle with the
air conditioner turned off until the pointer drops
back into the normal range. If the pointer remains on
the ªHº, turn the engine off immediately, and call for
service.
WARNING!
A hot engine cooling system is dangerous. You or
others could be badly burned by steam or boiling
coolant. You may want to call a service center if your
vehicle overheats. If you decide to look under the
hood yourself, see Section 7, Maintenance, of this
manual. Follow the warnings under the Cooling
System Pressure Cap paragraph.
JACKING AND TIRE CHANGING
WARNING!
²Getting under a jacked-up vehicle is dangerous.
The vehicle could slip off the jack and fall on you.
You could be crushed. Never get any part of your
body under a vehicle that is on a jack. Never start
or run the engine while the vehicle is on a jack. If
you need to get under a raised vehicle, take it to a
service center where it can be raised on a lift.
²Do not attempt to change a tire on the side of the
vehicle close to moving traffic. Pull far enough off
the road to avoid the danger of being hit when
operating the jack or changing the wheel.
WHAT TO DO IN EMERGENCIES 153
6

MAINTAINING YOUR VEHICLE
CONTENTS
m2.0L Engine Compartment...............165
mOnboard Diagnostic System Ð OBD II......166
mEmissions Inspection And Maintenance
Programs
............................167
mReplacement Parts.....................168
mDealer Service........................168
mMaintenance Procedures.................169
NEngine Oil..........................169
NIgnition Wiring System.................174
NCrankcase Emission Control System........174
NFuel Filter..........................175
NAir Cleaner Element (Filter)..............175NMaintenance-Free Battery................175
NAir Conditioner......................176
NPower Steering Fluid Check..............177
NFront Suspension Ball Joints..............178
NBody Lubrication.....................178
NWindshield Wiper Blades................178
NWindshield Wiper Blade Replacement.......179
NWindshield Washer Aiming..............179
NWindshield Washer Reservoir.............179
NExhaust System......................179
NCooling System.......................180
7

EMISSIONS INSPECTION AND MAINTENANCE
PROGRAMS
In some localities, it may be a legal requirement to pass
an inspection of your vehicle's emissions control system.
Failure to pass could prevent vehicle registration.
For states which have an I/M (Inspection and
Maintenance) requirement, this check verifies the
following: the MIL (Malfunction Indicator Lamp)
is functioning and is not on when the engine is running,
and that the OBD (On Board Diagnostic) system is ready
for testing.
Normally, the OBD system will be ready. The OBD
system maynotbe ready if your vehicle was recently
serviced, if you recently had a dead battery, or a battery
replacement. If the OBD system should be determined
not ready for the I/M test, your vehicle may fail the test.
Your vehicle has a simple ignition key actuated test
which you can use prior to going to the test station. To
check if your vehicle's OBD system is ready, you must do
the following:
1. Insert your ignition key into the ignition switch.2. Turn the ignition to the ON position, but do not crank
or start the engine.
3. If you crank or start the engine, you will have to start
this test over.
4. As soon as you turn your key to the ON position, you
will see your MIL symbol come on as part of a normal
bulb check.
5. Approximately 15 seconds later, one of two things will
happen:
a. The MIL will flash for about 10 seconds and then
return to being fully illuminated until you turn off
the ignition key or start the engine. This means that
your vehicle's OBD system isnot readyand you
shouldnotproceed to the I/M station.
b. The MIL will not flash at all and will remain fully
illuminated until you turn off the ignition key or
start the engine. This means that your vehicle's OBD
system isreadyand you can proceed to the I/M
station.
MAINTAINING YOUR VEHICLE 167
7

If your OBD system isnot ready,you should see your
authorized dealer or repair facility. If your vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive your
vehicle as you normally would in order for your OBD
system to update. A recheck with the above test routine
may then indicate that the system is now ready.
Regardless of whether your vehicle's OBD system is
ready or not ready, if the MIL symbol is illuminated
during normal vehicle operation, you should have your
vehicle serviced before going to the I/M station. The I/M
station can fail your vehicle because the MIL symbol is on
with the engine running.REPLACEMENT PARTS
Use of genuine Mopar parts for normal/scheduled main-
tenance and repairs is highly recommended to insure the
designed performance. Damage or failures caused by the
use of non-Mopar parts for maintenance and repairs will
not be covered by the manufacturer warranty.
DEALER SERVICE
Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service manuals are available which
include detailed service information for your vehicle.
Refer to these manuals before attempting any procedure
yourself.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
168 MAINTAINING YOUR VEHICLE

WARNING!
You can be badly injured working on or around a
motor vehicle. Do only that service work for which
you have the knowledge and the proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.
MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
Engine Oil
Checking Oil Level
To assure proper engine lubrication, the engine oil must
be maintained at the correct level. Check the oil level at
regular intervals, such as every fuel stop.
The best time to check the engine oil level is about 5
minutes after a fully warmed engine is shut off, or before
starting the engine after it has sat overnight.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Maintain
MAINTAINING YOUR VEHICLE 169
7

NOTE:IfANYof these apply to you then change your
engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule ªBº of the
9Maintenance Schedules9section of this manual.
If none of these apply to you, then change your engine oil
at every interval shown on schedule9A9of the9Mainte-
nance Schedules9section of this manual.
NOTE:Under no circumstances should oil change
intervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.
Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacture only
recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395.
American Petroleum Institute (API) Engine Oil
Identification Symbol
This symbol means that the oil has
been certified by the American
Petroleum Institute (API). The
manufacturer only recommends
API Certified engine oils.
Engine Oil Viscosity Chart
The proper SAE viscosity grade of engine oil should be
selected based on the following recommendation and be
within the operating temperature shown in the engine oil
viscosity chart.
MAINTAINING YOUR VEHICLE 171
7

Drive Belts Ð Check Condition and Tension
At the mileage shown in the maintenance schedules,
check all drive belts for condition and proper tension.
Improper belt tension can cause belt slippage and failure.
Inspect the drive belts for evidence of cuts, cracks, or
glazing and replace them if there is any sign of damage
which could result in belt failure. If adjustment is re-
quired, adjust the belts according to the specifications
and procedures shown in the Service Manual.
Special tools are required to properly measure tension
and to restore belt tension to factory specifications. Also,
check belt routing to make sure there is no interference
between the belts and other engine components.
Spark Plugs
Spark plugs must fire properly to assure engine perfor-
mance and emission control. New plugs should be in-
stalled at the specified mileage. The entire set should be
replaced if there is any malfunction due to a faulty spark
plug. Check the specifications section for the proper type
of spark plug for use in your vehicle.
Catalytic Converter
The catalytic converter requires the use of unleaded fuel
only. Leaded gasoline will destroy the effectiveness of the
catalyst as an emission control device.
Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.
CAUTION!
Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.
MAINTAINING YOUR VEHICLE 173
7

WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your ex-
haust system. Do not park or operate your vehicle in
areas where your exhaust system can contact any-
thing that can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may suggest severe
and abnormal catalyst overheating. If this occurs, stop
the vehicle, turn off the engine and allow it to cool.
Service, including a tune up to manufacturers specifica-
tions, should be obtained immediately.
To minimize the possibility of catalyst damage:
²Do not shut off the engine or interrupt the ignition
when the transaxle is in gear and the vehicle is in
motion.
²Do not try to start the engine by pushing or towing the
vehicle.
²Do not idle the engine with any spark plug wires
disconnected for prolonged period.
Engine Timing Belt
Replace the engine timing belt at the intervals described
in the appropriate maintenance schedule.
Ignition Wiring System
The ignition cables should be kept clean and properly
connected. Terminals should be fully seated. Cracked,
damaged, or faulty cables should be replaced.
Crankcase Emission Control System
Proper operation of this system depends on freedom
from sticking or plugging due to deposits. As vehicle
mileage builds up, the PCV valve and passages may
accumulate deposits. If a valve is not working properly,
replace it with a new valve. DO NOT ATTEMPT TO
CLEAN THE OLD PCV VALVE!
Check ventilation hose for indication of damage or
plugging deposits. Replace if necessary.
174 MAINTAINING YOUR VEHICLE