engine DODGE NEON 2004 2.G Repair Manual

of the engine compartment. This is normally a result of
moisture from rain, snow, or high humidity accumula-
tion on the radiator and being vaporized when the
thermostat opens, allowing hot water to enter the radia-
tor.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.
A. Do not overfill the coolant bottle.
B. Check coolant freeze point in the system.
C. If frequent coolant additions are required, the cooling
system should be pressure tested for leaks.
D. Maintain coolant concentration at 50% ethylene glycol
antifreeze (minimum) in water for proper corrosion pro-
tection of your engine which contains aluminum compo-
nents.
E. Make sure that the radiator and coolant bottle hoses
are not kinked or obstructed.F. Keep the front of the radiator clean. If your vehicle has
air conditioning, keep the front of the condenser clean,
also.
G. Do not change the thermostat for summer or winter
operation. If replacement is ever necessary, install ONLY
the correct type thermostat. Other designs may result in
unsatisfactory coolant performance, poor gas mileage,
and increased emissions.
Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, checking, tear, cuts, abrasions,
and excessive swelling indicate deterioration of the rub-
ber.
Pay particular attention to the hoses nearest to high heat
sources such as the exhaust manifold. Inspect hose rout-
ing to be sure hoses do not touch any heat source or
moving component that may cause heat damage or
mechanical wear.
Insure nylon tubing in these areas has not melted or
collapsed.
184 MAINTAINING YOUR VEHICLE

NOTE:Inspection of brake hoses should be done
whenever the brake system is serviced and every engine
oil change.
WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
Brake Master Cylinder
The fluid level in the master cylinder should be checked
when performing under hood services, or immediately if
the brake system warning lamp is on.
Be sure to clean the top of the master cylinder area before
removing the cap. If necessary, add fluid to bring the
fluid level up to the requirements described on the brake
fluid reservoir. Fluid level can be expected to fall as the
brake pads wear. Brake fluid level should be checked
when pads are replaced. However, low fluid level may be
caused by a leak and a checkup may be needed.Use only manufacturers recommended brake fluid, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
WARNING!
Use of a brake fluid that may have a lower initial
boiling point or unidentified as to specification, may
result in sudden brake failure during hard pro-
longed braking. You could have an accident.
186 MAINTAINING YOUR VEHICLE

WARNING!
Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter.
Do not allow petroleum based fluid to contaminate the
brake fluid as seal damage will result!
Automatic Transaxle
All front wheel drive vehicles have a transaxle and
differential assembly contained within a single housing.
Selection of Lubricant
It is important that the proper lubricant is used in the
transaxle to assure optimum transaxle performance. Use
only manufacturers recommended transmission fluid,
refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type. It is important that the
transmission fluid be maintained at the prescribed level
using the recommended fluid.
CAUTION!
Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
Fluid Level Check
The fluid level in the automatic transaxle should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transaxle and of the fluid.
Procedure for Checking Fluid Level
Check the fluid level while the transmission is at normal
operating temperature. This occurs after at least 15 miles
(25 km) of driving. At normal operating temperature,
which is approximately180ÉF ( 82ÉC), the fluid cannot be
held comfortably between the fingertips.
MAINTAINING YOUR VEHICLE 187
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To check the fluid level properly, the following procedure
must be used:
1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for at
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector momentarily in each gear
position ending with the lever in P (PARK).
5. Remove the dipstick, wipe it clean and reinsert it until
seated.
6. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be in the crosshatch
area at normal operating temperatures. If the fluid is low,
add as required into the dipstick tube.Do not overfill.
NOTE:If it is necessary to check the transmission
belowthe operating temperature, the fluid level should
be between the two COLD (lower) holes on the dipstick
with the fluid at approximately 80ÉF (27ÉC) (room tem-
perature). If the fluid level is correctly established at
room temperature, it should be between the HOT (upper)reference holes when the transmission reaches 180ÉF
(82ÉC). Remember it is best to check the level at the
normal operating temperature.
If the fluid level shows low, add sufficient transmission
fluid to bring to the proper level.
188 MAINTAINING YOUR VEHICLE

FUSES
Underhood Fuses (Power Distribution Center)
A Power Distribution Center is located in the engine
compartment; next to the battery. A label identifying the
components and circuits is located on the underside of
the cover.
Interior Fuses
The fuse access panel is behind the end cover at the left
side of the instrument panel. To remove the panel, pull it
out, as shown. A diagram identifying the components
and circuits is located on the inside of the cover.
MAINTAINING YOUR VEHICLE 195
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FLUIDS AND CAPACITIES
U.S. Metric
Fuel (Approximate)
Standard 2.0L Engines 87 Octane 12.5 Gallons 47.5 Liters
High Output 2.0L Engines 91 Octane 12.5 Gallons 47.5 Liters
Engine Oil-With Filter
2.0 Liter Engines (SAE 5W-30, API Certified Engine Oils) 4.5 qts 4.3 Liters
Cooling System *
2.0 Liter Engines (MopartAntifreeze/Coolant 5 Year/100,000
Mile Formula)6.5 qts 6.2 Liters
* Includes heater and coolant recovery bottle filled to MAX level.
200 MAINTAINING YOUR VEHICLE

RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine
Component Fluids, Lubricants and Genuine Parts
Engine Coolant MopartAntifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or-
ganic Additive Technology)
Engine Oil Use API Certified SAE 5W-30 Engine Oil. Refer to oil viscosity chart for cor-
rect SAE grade meeting DaimlerChrysler Material Standard MS-6395.
Engine Oil Filter Mopar 4105409 or equiv.
Spark Plugs Refer to the Vehicle Emission Control Information label in the engine com-
partment.
Fuel Selection 91 Octane for 2.0L H.O. and 87 Octane for 2.0L Standard Engine.
Chassis
Component Fluids, Lubricants and Genuine Parts.
Automatic Transmission MopartATF+4 Automatic Transmission Fluid.
Manual Transmission Fluid MopartATF+4 Automatic Transmission Fluid.
Brake Master Cylinder MopartDOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not
available, then DOT 4 is acceptable. Use only recommended brake fluids.
Power Steering Reservoir MopartATF+4 Automatic Transmission Fluid.
MAINTAINING YOUR VEHICLE 201
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EMISSION CONTROL SYSTEM MAINTENANCE
The ªScheduledº maintenance services, listed inbold
typemust be done at the times or mileages specified to
assure the continued proper functioning of the emission
control system. These, and all other maintenance services
included in this manual, should be done to provide best
vehicle performance and reliability. More frequent main-
tenance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the
emission control devices and systems on your vehicle
may be performed by any automotive repair establish-
ment or individual using any automotive part which has
been certified pursuant to U.S. EPA or, in the State of
California, California Air Resources Board regulations.
MAINTENANCE SCHEDULES
There are two maintenance schedules that show the
requiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.
²Day or night temperatures are below 32ÉF (0ÉC).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16.2 km).
²More than 50% of your driving is sustained high
speeds during hot weather, above 90ÉF (32ÉC).
²Trailer towing.²L
²Taxi, police or delivery service (commercial ser-
vices).²L
²Off-road or desert operation.
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²If equipped for and operating with E-85 (ethanol)
fuel.
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.
NOTE:Most vehicles are operated under the conditions
listed for Schedule9B9.
Second is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under Sched-
ule9B9.
Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop for Fuel
²
Check the engine oil level about 5 minutes after a fully
warmed engine is shut off. Checking the oil level while
the vehicle is on level ground will improve the accu-
racy of the oil level reading. Add oil only when the
level is at or below the ADD or MIN mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²
Check tire pressure and look for unusual wear or
damage.
²Inspect the battery and clean and tighten the terminals
as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and add
as needed.
²Check all lights and all other electrical items for correct
operation.
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²Check rubber seals on each side of the radiator for
proper fit.
At Each Oil Change
²
Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints and front suspension compo-
nents.
²Check the automatic transaxle fluid level.
²Check the manual transaxle fluid level and fill plug
condition.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval shown on
Schedule ªAº 6,000 miles (10 000 km) or every other
interval shown on Schedule ªBº 6,000 miles (10 000
km).
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