DODGE NEON 2005 2.G Owners Manual

Cooling System
WARNING!
²When working near the radiator cooling fan, dis-
connect the fan motor lead or turn the ignition
switch to the OFF position. The fan is temperature
controlled and can start at any time the ignition
switch 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 engine coolant (antifreeze) 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. Check the front of the A/C condenser for any
accumulation of bugs, leaves, etc. If dirty, clean by gently
spraying water from a garden hose vertically down the
face of the condenser.
Check the coolant recovery bottle tubing for brittle rubber,
cracking, tears, cuts and tightness of the connection at the
bottle and radiator. Inspect the entire system for leaks.
With the engine at normal operating temperature (but
not running), check the cooling system pressure cap for
proper vacuum sealing by draining a small amount of
coolant from the radiator drain cock. If the cap is sealing
properly, the engine coolant (antifreeze) will begin to
drain from the coolant recovery bottle. DO NOT RE-
MOVE THE COOLANT PRESSURE CAP WHEN THE
COOLING SYSTEM IS HOT.
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Cooling System Ð Drain, Flush and Refill
At the intervals shown on the Maintenance Schedules,
the system should be drained, flushed and refilled.
If the solution is dirty or contains a considerable amount
of sediment, clean and flush with a reliable cooling
system cleaner. Follow with a thorough rinsing to remove
all deposits and chemicals. Properly dispose of old
antifreeze solution.
Selection Of Coolant
Use only the manufacturers recommended coolant, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct coolant type.
CAUTION!
Mixing of coolants other than specified HOAT en-
gine coolants, may result in engine damage and may
decrease corrosion protection. If a non-HOAT cool-
ant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
Do not use plain water alone or alcohol base engine
coolant (antifreeze) products. Do not use additional
rust inhibitors or antirust products, as they may not
be compatible with the radiator engine coolant and
may plug the radiator.
This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propylene
Glycol based coolants is not recommended.
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Adding Coolant
Your vehicle has been built with an improved engine
coolant that allows extended maintenance intervals. This
coolant can be used up to 5 Years or 100,000 miles before
replacement. To prevent reducing this extended mainte-
nance period, it is important that you use the same
coolant throughout the life of your vehicle. Please review
these recommendations for using Hybrid Organic Addi-
tive Technology (HOAT) coolant.
When adding coolant, a minimum solution of 50% rec-
ommended Mopar Antifreeze/ Coolant 5 Year/100,000
Mile Formula HOAT (Hybrid Organic Additive Technol-
ogy), or equivalent, in water should be used. Use higher
concentrations (not to exceed 70%) if temperatures below
234ÉF (237ÉC ) are anticipated.
Use only high purity water such as distilled or deionized
water when mixing the water/engine coolant solution.
The use of lower quality water will reduce the amount of
corrosion protection in the engine cooling system.Please note that it is the owner's responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.
NOTE:Mixing coolant types will decrease the life of the
engine coolant and will require more frequent coolant
changes.
Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of
coolant, and to insure that coolant will return to the
radiator from the coolant recovery bottle.
The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.
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WARNING!
²The warning words ªDO NOT OPEN HOTº on
the cooling system pressure cap are a safety pre-
caution. 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.
²Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or
engine damage may result.
Disposal of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. To prevent ingestion by animals or children
do not store ethylene glycol based engine coolant in open
containers or allow it to remain in puddles on the
ground. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
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 ranges indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant 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 (a
few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
184 MAINTAINING YOUR VEHICLE

humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot coolant to
enter the radiator.
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.
²Do not overfill the coolant recovery bottle.
²Check coolant freeze point in the radiator and in the
coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.
²If frequent coolant additions are required, or if the
level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.
²Maintain coolant concentration at 50% HOAT engine
coolant (minimum) and distilled water for proper
corrosion protection of your engine which contains
aluminum components.
²Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
²Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean, also.
²Do 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.
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7

Insure nylon tubing in these areas has not melted or
collapsed.
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.
186 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.
Brake Fluid Master Cylinder
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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 approximately 180ÉF ( 82ÉC), the fluid cannot be
held comfortably between the fingertips.
188 MAINTAINING YOUR VEHICLE

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 a
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.
MAINTAINING YOUR VEHICLE 189
7

CAUTION!
Do not overfill. Dirt and water in the transaxle can
cause serious damage. To prevent dirt and water
from entering the transaxle after checking or replen-
ishing fluid, make certain that the dipstick cap is
seated properly.
Fluid and Filter Changes
Automatic transmission fluid and filter should be
changed as follows:
Maintenance schedule ªAºÐ No change necessary.
Maintenance schedule ªBº± Every 60,000 miles (96 000
km) change fluid and filter under the following condi-
tions:
²Police, taxi, limousine, commercial type operation, or
trailer towing where the vehicle is drivenregularlyfor
more than 45 minutes of continuous operation.
NOTE:Refer to Section 8 of this manual for mainte-
nance schedules.If the transaxle is disassembled for any reason, the fluid
and filter should be changed.
Special Additives
The manufacturer recommends against the addition of
any fluid additives to the transaxle. The only exception to
this policy is the use of special dyes to aid in detecting
fluid leaks. The use of transmission sealers should be
avoided as they may adversely affect seals.
Manual Transaxle
Lubricant Selection
Use only manufacturers recommended transmission
fluid, refer to Recommended Fluids, Lubricants and
Genuine Parts for correct fluid type.
Fluid Level Check
Check the fluid level by removing the fill plug. The fluid
level should be between the bottom of the fill hole and a
point not more that 3/16º (4.76 mm) below the bottom of
the hole.
Add fluid, if necessary, to maintain the proper level.
190 MAINTAINING YOUR VEHICLE