warning DODGE NEON 2004 2.G Repair Manual

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

Fuel Filter
A plugged fuel filter can cause hard starting or limit the
speed at which a vehicle can be driven. Should an
excessive amount of dirt accumulate in the fuel tank,
frequent filter replacement may be necessary.
Air Cleaner Element (Filter)
Under normal driving conditions, replace the filter at the
intervals shown on Schedule ªAº. If, however, you drive the
vehicle frequently under dusty or severe conditions, the
filter element should be inspected periodically and replaced
if necessary at the intervals shown on Schedule ªBº.
WARNING!
The air cleaner can provide a measure of protection
in the case of engine backfire. Do not remove the air
cleaner unless such removal is necessary for repair or
maintenance. Make sure that no one is near the
engine compartment before starting the vehicle with
the air cleaner removed. Failure to do so can result in
serious personal injury.
Maintenance-Free Battery
The top of the MAINTENANCE-FREE battery is perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.
CAUTION!
When servicing the battery, always reinstall the
battery thermowrap. The thermowrap provides bat-
tery heat protection and will extend overall battery
life. Failure to reinstall the thermowrap can result in
evaporative loss of the battery fluid.
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WARNING!
Battery posts, terminals and related accessories con-
tain lead and lead compounds. Wash hands after
handling.
Battery fluid is a corrosive acid solution and can
burn or even blind you. Don't allow battery fluid to
contact your eyes, skin or clothing. Don't lean over a
battery when attaching clamps. If acid splashes in
eyes or on skin, flush the area immediately with
large amounts of water.
Battery gas is flammable and explosive. Keep flame
or sparks away from the battery. Don't use a booster
battery or any other booster source with an output
greater than 12 volts. Don't allow cable clamps to
touch each other.
CAUTION!
It is essential when replacing the cables on the
battery that the positive cable is attached to the
positive post and the negative cable is attached to the
negative post. Battery posts are marked positive (+)
and negative (-) and identified on the battery case.
Cable clamps should be tight on the terminal posts
and free of corrosion. Apply grease to posts and
clamps after tightening.
If a ªfast chargerº is used while the battery is in the
vehicle, disconnect both vehicle battery cables be-
fore connecting the charger to battery. Do not use a
ªfast chargerº to provide starting voltage as battery
damage can result.
Air Conditioner
Check the air conditioning system at the start of the
warm weather season.
NOTE:If your air conditioning performance seems
lower than expected, check the front of the A/C con-
denser for an accumulation of dirt or insects. Clean with
176 MAINTAINING YOUR VEHICLE

a gentle water spray from behind the radiator and
through the condenser as required. Fabric front fascia
protectors may reduce air flow to the condenser, reducing
air conditioning performance.
WARNING!
The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal injury
or damage to the system, adding refrigerant or any
repair requiring lines to be disconnected should be
done by an experienced repairman.
Refrigerant Recovery And Recycling
The air conditioning system of your vehicle contains
R-134a, a refrigerant that does not deplete the ozone layer
in the upper atmosphere, the manufacturer recommends
that air conditioning service be done by facilities using
refrigerant recycling and recovery equipment that meets
SAE standard J1991.
NOTE:Air Conditioning systems found to be contami-
nated with A/C System Sealers, Stop Leak Products, SealConditioners, Compressor Oils, or Refrigerants not ap-
proved by the manufacturer, voids the warranty for the
Air Conditioning system.
Power Steering Fluid Check
Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.
WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.
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into the passenger compartment. In addition, inspect the
exhaust system each time the vehicle is raised for lubri-
cation or oil change. Replace as required.
WARNING!
Exhaust gases can injure or kill. They contain carbon
monoxide which is colorless and odorless. Breathing
it can make you unconscious and can eventually
poison you. Follow the above precautions to keep
your exhaust system as safe as possible.
Cooling System
WARNING!
²When working near the radiator cooling fan, dis-
connect the fan motor lead or turn the ignition key
to the OFF position. The fan is temperature con-
trolled and can start at any time the ignition key is
in the ON position.
²You or others can be badly burned by hot coolant
or steam from your radiator. If you see or hear
steam coming from under the hood, don't open
the hood until the radiator has had time to cool.
Never try to open a cooling system pressure cap
when the radiator is hot.
Coolant Checks
Check coolant protection every 12 months (before the
onset of freezing weather, where applicable). If coolant is
dirty or rusty in appearance, the system should be
drained, flushed and refilled with fresh coolant.
180 MAINTAINING YOUR VEHICLE

The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.
WARNING!
The warning words ªDO NOT OPEN HOTº on the
cooling system pressure cap are a safety precaution.
never add coolant when the engine is overheated. Do
not loosen or remove the cap to cool an overheated
engine. Heat causes pressure to build up in the
cooling system. To prevent scalding or injury, do not
remove the pressure cap while the system is hot or
under pressure.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine idling, and warm to normal operating tempera-
ture, the level of the coolant in the bottle should be
between the ªFULLº and ªADDº marks.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking forcoolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.
When additional coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.
Points to Remember
NOTE:
When the vehicle is stopped after a few miles of
operation, you may observe vapor coming from the front
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Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of degradation that could cause failure.
Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Section.
WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn't have your full
braking capacity in an emergency.
Brake and Power Steering System Hoses
When servicing the vehicle for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, checking, tears, cuts, abrasions, and excessive
swelling suggest deterioration of the rubber. Particular
attention should be made to examining those hose sur-
faces nearest to high heat sources, such as the exhaust
manifold.
Inspect all hose clamps and couplings to make sure they
are secure and no leaks are present.
Insure nylon tubing in these areas has not melted or
collapsed.
NOTE:Often, fluids such as oil, power steering fluid,
and brake fluid are used during assembly plant opera-
tions to ease the assembly of hoses to couplings. There-
fore, oil wetness at the hose-coupling area is not neces-
sarily an indication of leakage. Actual dripping of hot
fluid when systems are under pressure (during vehicle
operation) should be noted before hose is replaced based
on leakage.
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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.
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Interior Care
Use Mopar Fabric Cleaner to clean fabric upholstery and
carpeting.
Use Mopar Vinyl Cleaner to clean vinyl upholstery.
Mopar Vinyl Cleaner is specifically recommended for
vinyl trim.
Your leather upholstery can be best preserved by regular
cleaning with a damp soft cloth. Small particles of dirt
can act as an abrasive and damage the leather upholstery
and should be removed promptly with a damp cloth.
Stubborn soils can be removed easily with a soft cloth
and Mopar Total Clean. Care should be taken to avoid
soaking your leather upholstery with any liquid. Please
do not use polishes, oils, cleaning fluids, solvents, deter-
gents, or ammonia based cleaners to clean your leather
upholstery. Application of a leather conditioner is not
required to maintain the original condition.WARNING!
Do not use volatile solvents for cleaning purposes.
Many are potentially flammable, and if used in
closed areas they may cause respiratory harm.
Cleaning Headlights
Your vehicle has plastic headlights that are lighter and
less susceptible to stone breakage than glass headlights.
Plastic is not as scratch resistant as glass and therefore
different lens cleaning procedures must be followed.
To minimize the possibility of scratching the lenses and
reducing light output, avoid wiping with a dry cloth. To
remove road dirt, wash with a mild soap solution fol-
lowed by rinsing.
Do not use abrasive cleaning components, solvents, steel
wool or other aggressive material to clean the lenses.
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