1999 DODGE NEON Service Repair Manual

EGR TUBE
The EGR tube attaches to the intake manifold ple-
num below the throttle body and EGR valve.
REMOVAL
(1) Remove screws attaching EGR tube to intake
manifold (Fig. 6).
(2) Remove EGR tube to EGR valve screws.
(3) Remove EGR tube. Clean gasket surface on the
EGR valve. Wipe clean the grommet on the intake
manifold.
INSTALLATION
The rubber grommet that seals the EGR tube to
intake manifold connection is reusable.
(1) Loosely install the EGR tube and fasteners.(2) Tighten the EGR tube to intake manifold ple-
num screws to 11 N´m (95 in. lbs) torque.
(3) Tighten the EGR tube to EGR valve screws to
11 N´m (95 in. lbs.) torque.
SPECIFICATIONS
TORQUE
Description Torque
EGR valve to cyl. head........22N´m(200 in. lbs.)
EGR tube to EGR valve............11(95in.lbs.)
EGR tube to intake manifold....11N´m(95in.lbs.)
Fig. 5 EGR SystemFig. 6 EGR Tube Stud Bolts
25 - 22 EMISSION CONTROL SYSTEMSPL
REMOVAL AND INSTALLATION (Continued)

EMISSION CONTROL SYSTEMÐ1.8L ENGINE
CONTENTS
page page
GENERAL INFORMATION
EMISSION CONTROL SYSTEMÐ1.8L SOHC
ENGINE............................. 1
GENERAL INFORMATION
EMISSION CONTROL SYSTEMÐ1.8L SOHC
ENGINE
The emission control system used on the 1.8L
SOHC engine operates the same as the emission con-
trol system used on the 2.0L SOHC engine. It alsocontains the same components as the 2.0L engine,
and the service procedures are the same. Refer to
group 25 for the 2.0L engine in this manual for a
complete description of the fuel system and its ser-
vice procedures.
PLEMISSION CONTROL SYSTEMÐ1.8L ENGINE 25 - 1

INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE EMBOSS.................... 3
BODY CODE EMBOSS/PLATE............... 2
BODY CODE PLATE...................... 3
FASTENER IDENTIFICATION................ 5INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS.................... 5
METRIC SYSTEM........................ 8
STANDARD BODY DIMENSIONS............ 4
TORQUE REFERENCES................... 10
VEHICLE IDENTIFICATION NUMBER......... 1
VEHICLE SAFETY CERTIFICATION LABEL..... 2
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) is located
on the upper left corner of the instrument panel,
near the left A-Pillar. The VIN consists of 17 charac-
ters in a combination of letters and numbers that
provide specific information about the vehicle (Fig.
1). Refer to VIN Code Decoding Chart.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
Fig. 1 Vehicle Identification Number
PLINTRODUCTION 1

VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is
attached to the rear facing of the driver's door. This
label indicates date of manufacture (month and
year), Gross Vehicle Weight Rating (GVWR), Gross
Axle Weight Rating (GAWR) front, Gross Axle Weight
Rating (GAWR) rear and the Vehicle Identification
Number (VIN). The Month, Day and Hour of manu-
facture is also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
BODY CODE EMBOSS/PLATE
Depending on which plant the vehicle is manufac-
tured, it may be equipped with a Body Code Emboss
or a Body Code Plate.
VIN CODE DECODING
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin1 = United states
3 = Mexico
2 MakeB = Dodge
P = Plymouth
3 Vehicle Type 3 = Passenger Car
4 Pass. Safety E = Active Restraints, Driver & Passenger Airbags
5 Car Line S = Neon/Neon Expresso
6 Series2 = Low Line
4 = High Line
6 = Sport
7 Body Style2 = 2 Door Pillared Hardtop
7 = 4 Door Pillared Hardtop
8 EngineC = 2.0L 4 Cyl. 16V
Y = 2.0L 4 Cyl. DOHC
9 Check Digit See explanation in this section.
10 Model Year W = 1998
11 Assembly PlantD = Belvidere
T = Toluca
12 Thru 17 Vehicle Build Sequence 6 digit number assigned by assembly plant.
Fig. 2 Vehicle Safety Certification Label
2 INTRODUCTIONPL
GENERAL INFORMATION (Continued)

BODY CODE EMBOSS
The Body Code Emboss is located in the engine
compartment on the front of the right strut tower.
There are two lines of information in the body code
emboss.
BODY CODE EMBOSS LINE 1
Line 1 contains the Vehicle Identification Number
(VIN). Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
BODY CODE EMBOSS LINE 2
DIGITS 1-3ÐPaint Code
Refer to Group 23, Body for paint information.
DIGITS 4-7ÐTrim Code
Refer to Parts Catalog for more information.
DIGITS 5-10ÐOpen
DIGITS 11-14ÐVehicle Order Number
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate is located in the engine com-
partment on the radiator closure panel. There are
seven lines of information on the body code plate.
Lines 4, 5, 6, and 7 are not used to define service
information. Information reads from left to right,
starting with line 3 in the center of the plate to line
1 at the bottom of the plate.
BODY CODE PLATE ± LINE 3
DIGITS 1, 2, AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Primary paint
See Group 23, Body for color codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Paint
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open SpaceDIGITS 20, 21, AND 22
Engine Code
²ECB = 2.0L Four Cylinder SOHC Gasoline
²ECC = 2.0L Four Cylinder DOHC Gasoline
BODY CODE PLATE LINE 2
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, THROUGH 15
Vinyl Roof Code
DIGITS 16 AND 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
²PL
DIGITS 20
Carline
²C = Chrysler
²D = Dodge
²H = Plymouth
DIGIT 21
Price Class
²E = Economy
²H = High Line
²L = Low Line
²M = Mid Line
²P = Premium
²S = Special/Sport
²X = Performance Image
DIGITS 20 AND 21
Body Type
²22 = Two Door Sedan
²42 = Four Door Sedan
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGA = 31TH 3-Speed Automatic Transaxle
²DD4 = NV T350 5-Speed Manual Transaxle
²DD5 = NV T350 5-Speed Manual Transaxle
DIGIT 4
Open Space
PLINTRODUCTION 3
GENERAL INFORMATION (Continued)

DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
STANDARD BODY DIMENSIONS
INTERIOR DIMENSIONS
CARBODY
STYLEHEAD ROOM LEG ROOM SHOULDER ROOM HIP ROOM
FRONT REAR FRONT REAR FRONT REAR FRONT REAR
PL PL-421005 mm 928 mm 1080 mm 891 mm 1333 mm 1329 mm 1290 mm 1286 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.5 in. 52.3 in. 50.8 in. 50.6 in.
PL PL-221005 mm 928 mm 1080 mm 891 mm 1321 mm 1391 mm 1277 mm 1369 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.0 in. 54.7 in. 50.3 in. 53.9 in.
EXTERIOR DIMENSIONS
CARBODY
STYLEWHEEL
BASEFRONT
TRACKREAR
TRACKOVERALL
LENGTHOVERALL
WIDTHOVERALL
HEIGHT
mm/in. mm/in. mm/in. mm/in. mm/in. mm/in.
PL PL-42 2642/104 1458/57.4 1458/57.4 4364/171.8 1708/67.2 1395/54.9
PL PL-22 2642/104 1458/57.4 1458/57.4 4364/171.8 1711/67.4 1395/54.9
4 INTRODUCTIONPL
GENERAL INFORMATION (Continued)

INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
The graphic symbols illustrated in the following
chart (Fig. 3) are used to identify various instrument
controls. The symbols correspond to the controls and
displays that are located on the instrument panel.
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart (Fig. 4).
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greaterthe bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 12.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 3
Fig. 4 Thread NotationÐSAE and Metric
PLINTRODUCTION 5
GENERAL INFORMATION (Continued)