1999 DODGE NEON Service Repair Manual

(13) Remove accelerator, kickdown and speed con-
trol cables from throttle lever and bracket. Refer to
Group 14, Fuel System Throttle Body Removal for
procedures.
(14) Disconnect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors
(Fig. 25).
(15) Disconnect vacuum hoses from throttle body.
(16) Remove throttle body.
(17) Disconnect Manifold Absolute Pressure/In-
take Air Temperature sensor (TMAP) electrical con-
nector. Disconnect vapor and brake booster hoses
(Fig. 26).(18) Disconnect knock sensor electrical connector
and disconnect wiring harness from tab located on
the heater tube (Fig. 27).
(19) Disconnect wiring from starter.
(20) Remove EGR tube bolts at the valve and at
the intake manifold (Fig. 28). Remove tube from
engine.
(21) Remove intake manifold fasteners. Remove
intake manifolds (upper and lower).
Fig. 25 Idle Air Control (IAC) Motor and Throttle
Position Sensor (TPS) Wiring Connectors
Fig. 26 Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) Electrical Connector
Fig. 27 Knock Sensor Electrical
Fig. 28 EGR Tube Assembly
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.
29) to 28 N´m (250 in. lbs.).
(2) Install intake manifold onto cylinder head and
tighten fasteners to 28 N´m (250 in. lbs.) in sequence
shown in (Fig. 30).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect heater tube and hose to intake mani-
fold.
(7) Connect upper radiator hose and coolant recov-
ery hose.
(8) Connect coolant temperature sensor wiring con-
nector.
(9) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.).
(10) Connect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP) wiring connector.(11) Connect knock sensor connector and starter
wires. Connect wiring harness to heater tube tab.
(12) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(13) Connect vacuum hoses to throttle body.
(14) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(15) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(16) Install fresh air duct to air filter housing.
Tighten clamp to 3 N´m (25 in. lbs.).
(17) Connect negative cable to battery.
(18) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Remove air cleaner assembly and bracket.
(2) Remove exhaust manifold heat shield (Fig. 31).
(3) Disconnect upstream heated oxygen sensor con-
nector.
Fig. 29 Lower Intake Manifold to Upper Tightening
Sequence
Fig. 30 Intake Manifold To Cylinder Head Tightening
Sequence
Fig. 31 Exhaust Manifold Heat Shield
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

(4) Remove exhaust pipe from manifold. Discard
manifold to flex joint gasket, if LEV equipped.
(5) Remove (8) exhaust manifold retaining fasten-
ers and remove exhaust manifold and gasket (Fig.
32).
INSTALLATION
NOTE: Discard gasket and clean all gasket sur-
faces of manifolds and cylinder head.
(1) Position exhaust manifold and gasket in place.
Apply MopartStud and Bearing Mount to fasteners
and tighten to 23 N´m (200 in. lbs.) starting at center
and progressing outward in both directions. Repeat
this procedure until all fasteners are at specified
torque.
(2) Install exhaust manifold heat shield.
(3) Connect upstream heated oxygen sensor con-
nector.
(4) Install air cleaner bracket and assembly.
(5) Replace manifold to flex joint gasket, if LEV
equipped.
(6) Attach exhaust pipe and tighten fasteners to 28
N´m (250 in. lbs.).
CLEANING AND INSPECTION
INTAKE MANIFOLD SOHC
INSPECT AND CLEAN
Check for:
²Inspect manifold for cracks or distortions.
²Check for torn or missing O-rings at the mating
surface of the manifold (Fig. 33).
INTAKE MANIFOLD DOHC
INSPECT AND CLEAN
Check for:
²Inspect manifold for cracks or distortions.²Check for torn gasket at the mating surface of
the manifold.
EXHAUST MANIFOLD
CLEAN AND INSPECT
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head.
(2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion.
Replace manifold if necessary.
SPECIFICATIONS
TORQUE CHART
EGR Tube Attaching
Bolts.....................11N´m(95in.lbs.)
Exhaust Manifold to Exhaust Pipe
Nuts.....................27N´m(20ft.lbs.)
Exhaust Manifold Flange (LEV)
Nuts....................28N´m(250 in. lbs.)
Exhaust Manifold Mounting
Bolts....................23N´m(200 in. lbs.)
Intake Manifold MountingÐSOHC
Bolts....................12N´m(105 in. lbs.)
Intake Manifolds Upper and LowerÐDOHC
Bolts....................28N´m(250 in. lbs.)
Heat Shield Mounting (Body)
Bolts......................4N´m(35in.lbs.)
Exhaust System Band Clamps (Torca)
Fastener..................75N´m(55ft.lbs.)
Exhaust Manifold Heat Shield
Bolts....................23N´m(200 in. lbs.)
Fig. 32 Exhaust Manifold
Fig. 33 Intake Manifold O-Rings
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
GENERAL INFORMATION
EXHAUST SYSTEMS.................... 1
GENERAL INFORMATION
EXHAUST SYSTEMS
The exhaust system for a vehicle that uses leaded
fuel has a resonator, heat shield(s), tailpipe and muf-
fler (Fig. 1).
Fig. 1 Exhaust System Ð Leaded Fuel Vehicles
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

FRAME AND BUMPERS
CONTENTS
page page
BUMPERS............................... 1FRAMES................................ 3
BUMPERS
INDEX
page page
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA.................. 1
FRONT BUMPER REINFORCEMENT.......... 1REAR BUMPER FASCIA................... 1
REAR BUMPER REINFORCEMENT........... 2
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
(1) Remove nuts holding front bumper fascia
bracket to bottom of fender forward of front wheels.
(2) Remove screws holding front fascia to inner
wheelhouse.
(3) Remove bolts holding fascia to bumper rein-
forcement forward of radiator (Fig. 1).
(4) Remove bolts holding fascia to bottom of
bumper reinforcement.
(5) Separate fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install bolts holding fascia to bottom of bumper
reinforcement.
(3) Install bolts holding fascia to bumper reinforce-
ment forward of radiator (Fig. 1).
(4) Install screws holding front fascia to inner
wheelhouse.
(5) Install radiator grille, refer to Group 23, Body
for proper procedures.
FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front fascia.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Remove nuts holding reinforcement to radiator
closure panel (Fig. 2).
(4) Separate bumper reinforcement from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR BUMPER FASCIA
REMOVAL
(1) Release trunk lock and open trunk lid.
(2) Remove bolts holding fascia to tail closure
panel.
(3) Remove push±in fasteners holding fascia to
bottom of rear bumper reinforcement (Fig. 3).
Fig. 1 Front Bumper Fascia
PLFRAME AND BUMPERS 13 - 1

(4) Remove bolts holding fascia bracket to lower
quarter panels.
(5) Separate fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install bolts holding fascia bracket to lower
quarter panels.
(3) Install push±in fasteners holding fascia to bot-
tom of rear bumper reinforcement (Fig. 3).
(4) Install bolts holding fascia to tail closure panel.
REAR BUMPER REINFORCEMENT
REMOVAL
(1) Remove rear fascia.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Remove nuts holding reinforcement to rear clo-
sure panel (Fig. 4).(4) Separate bumper reinforcement from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 2 Front Bumper ReinforcementFig. 3 Rear Bumper Fascia
Fig. 4 Rear Bumper Reinforcement
13 - 2 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

FRAMES
INDEX
page page
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER....... 3
SPECIFICATIONS
STRUCTURAL DIMENSIONS................ 4TORQUE SPECIFICATIONS................ 10
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER
WARNING: IF SUSPENSION CROSSMEMBER IS
REPLACED DUE TO COLLISION DAMAGE, INSPECT
THE STEERING COLUMN TO STEERING GEAR
COUPLING FOR DAMAGE. REFER TO GROUP 19,
STEERING FOR INSTRUCTIONS.
Before removing front suspension crossmem-
ber, index mark location of crossmember on
frame to aid installation.
The front suspension crossmember must be prop-
erly installed to achieve design camber, caster set-
tings and wheel stagger. The crossmember can be
installed out of position on the frame rails due to its
design. Bolts and cage nuts hold the rear of the
crossmember to the frame torque boxes. Bolts and
J-nuts hold the front of the crossmember to the
frame rails. No designed in locating device is used to
position the crossmember in the vehicle. Before
removing the crossmember mark the frame torque
box around the rear mounting location to aid instal-
lation. A crossmember that is removed during service
must be installed in the same position from which it
was removed. To verify that crossmember is in the
proper position, refer to the dimensions provided.
Front end dimensions are gauged from the principal
locating point (PLP) holes located under the frame
torque boxes rearward of the front wheels. After
removal and installation of the crossmember is per-
formed, verify that front suspension alignment is
within specifications. If camber, caster settings and
wheel stagger is not within specifications, loosen and
reposition crossmember to bring suspension within
specifications. Refer to Group 2, Front Suspension
and Driveshaft for additional information.
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Using a suitable marking device, mark the out-
line of the suspension crossmember on the frame
torque box around the rear mounting location.(3) Remove front wheels from vehicle.
(4) Remove pinch bolts holding front ball joints to
spindles.
(5) Separate ball joints from spindles.
(6) Position a suitable lifting device under the
crossmember.
(7) Remove bolts holding suspension crossmember
to frame rails above lower control arms (Fig. 1).
(8) Remove bolts holding crossmember to frame
torque boxes and allow front of crossmember to
swing down.
(9) Remove bolts holding steering gear to cross-
member.
(10) Separate steering gear from crossmember.
(11) Tie steering gear to a suitable structure above
to support gear after crossmember is removed.
(12) Separate front suspension crossmember from
vehicle.
INSTALLATION
If a new crossmember is to be installed, transfer
stabilizer bar and lower control arms from original
crossmember. Refer to Group 2, Suspension and
Driveshaft for proper procedures.
(1) Place front suspension crossmember in position
on vehicle.
(2) Remove tie device supporting steering gear.
Fig. 1 Front Suspension Crossmember
PLFRAME AND BUMPERS 13 - 3