1999 DODGE NEON engine

not more than 25 km (15 miles). The gear selector
must be in the neutral position.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components, damage to vehicle can result.
Do not attempt to raise one entire side of the
vehicle by placing a floor jack midway between the
front and rear wheels. This practice may result in
permanent damage to the body.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a PL vehicle (Fig. 3). Support the vehicle in the
raised position with jack stands.
A floor jack must never be used on any part of the
underbody.
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 3).
Fig. 3 Hoisting and Jacking Points
PLLUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel
Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or Grinding On
Turns1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Engine Mount Grounding
Against Frame Or Body Of Vehicle.2. Check For Motor Mount Hitting
Frame Rail And Reposition Engine
As Required
3. Worn Or Broken C/V Joint 3. Replace C/V Joint
4. Loose Wheel Lug Nuts 4. Verify Wheel Lug Nut Torque
5. Incorrect Wheel Alignment 5. Check And Reset Wheel
Alignment
6. Worn Tires 6. Replace Tires
Front End Clunk Or Snap On
Turns1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
3. Worn Or Loose Tie Rod Or Ball
Joint3. Tighten Or Replace Tie Rod End
Or Ball Joint
4. Worn Control Arm Bushing 4. Replace Control Arm Bushing
5. Loose Sway Bar Or Upper Strut
Attachment5. Tighten Sway Bar Or Upper Strut
Attachment To Specified Torque
Front End Whine With Vehicle
Going Straight At A Constant
Speed1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel
Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed1. Engine Mount Grounding 1. Reposition Engine As Required
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
Front End Whine When
Accelerating Or Decelerating1. Worn Or Defective Transaxle
Gears Or Bearings1. Replace Transaxle Gears Or
Bearings
Front End Clunk When
Accelerating Or Decelerating1. Worn Or Broken Engine Mount 1. Replace Engine Mount
2. Worn Or Defective Transaxle
Gears Or Bearings2. Replace Transaxle Gears Or
Bearings
3. Loose Wheel Lug Nuts 3. Verify Wheel Lug Nut Torque
4. Worn Or Broken C/V Joint 4. Replace C/V Joint
5. Worn Or Loose Ball Joint 5. Tighten Or Replace Ball Joint
6. Worn Or Loose Control Arm
Bushing6. Tighten To Specified Torque Or
Replace Control Arm Bushing
7. Loose Crossmember Bolts 7. Tighten Crossmember Bolts To
Specified Torque
PLSUSPENSION 2 - 3

boosters differ at the interface to the master cylinder.
If the power brake booster requires replacement be
sure it is replaced with the correct part.
The power brake booster can be identified by the
tag attached to the body of the booster assembly (Fig.
16). This tag contains the following information: The
production part number of the power booster assem-
bly, the date it was built, who manufactured it, and
brake sales code.
NOTE: The power brake booster assembly is not a
repairable part and must be replaced as a complete
unit if it is found to be faulty in any way. The power
booster vacuum check valve is not repairable but
can be replaced as an assembly.The power brake booster reduces the amount of
force required by the driver to obtain the necessary
hydraulic pressure to stop vehicle.
The power brake booster is vacuum operated. The
vacuum is supplied from the intake manifold on the
engine through the power brake booster check valve
(Fig. 16).
As the brake pedal is depressed, the power booster
input rod moves forward (Fig. 17). This opens and
closes valves in the power booster, allowing atmo-
spheric pressure to enter on one side of a diaphragm.
Engine vacuum is always present on the other side.
This difference in pressure forces the output rod of
the power booster (Fig. 17) out against the primary
piston of the master cylinder. As the pistons in the
master cylinder move forward this creates the
hydraulic pressure in the brake system.
Different engine options available for this vehicle
require that different vacuum hose routings be used.
The power brake vacuum booster assembly mounts
on the engine side of the dash panel. It is connected
to the brake pedal by the input push rod (Fig. 17). A
vacuum line connects the power booster to the intake
manifold. The master cylinder is bolted to the front
of the power brake vacuum booster assembly.
RED BRAKE WARNING LAMP
The red Brake warning lamp is located in the
instrument panel cluster and is used to indicate a
low brake fluid condition or that the parking brake is
applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch
when the ignition switch is placed in the crank posi-
tion. Problems with this system will generally be of
the type where the warning lamp fails to turn on
when it should, or remains on when it should not.
The warning lamp bulb is supplied a 12 volt igni-
tion feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit
Fig. 14 Master Cylinder For Antilock Brake
Equipped Vehicles
Fig. 15 Non-ABS Master Cylinder Primary And
Secondary Ports
Fig. 16 Power Brake Booster Identification
PLBRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
SYMPTOMCHART 1
MISC.
COND.CHART 2
WARNING
LIGHTCHART 3
POWER
BRAKESCHART 4
BRAKE
NOISECHART 5
WHEEL
BRAKES
Brake Warning Light On X NO NO
Excessive Pedal Travel 6 X NO O
Pedal Goes To The Floor 6 X
Stop Light On Without Brakes 3
All Brakes Drag 5
Rear Brakes Drag 2 NO NO
Grabby Brakes O X
Spongy Brake Pedal X NO
Premature Rear Brake Lockup 4 NO NO O
Excessive Pedal Effort 1 O
Rough Engine Idle NO O
Brake Chatter (Rough) NO NO X
Surge During Braking NO NO X
Noise During Braking NO NO X
Rattle Or Clunking Noise NO NO X
Pedal Pulsates During Braking NO NO X
Pull To Right Or Left NO NO X
No: Not A Possible Cause X: Most Likely Cause O: Possible Cause
PLBRAKES 5 - 9

MASTER CYLINDER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, be sure engine is
not running, and pump the brake pedal until a firm
pedal is achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector, from
brake fluid level sensor, in master cylinder brake
fluid reservoir (Fig. 103).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 104) and (Fig.
105). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner product such as Mopar Brake
Parts Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 106) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 107) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 107) located in the front of the power
brake vacuum booster. Vacuum seal is removed by
Fig. 102 Caliper Guide Pin Bolts
Fig. 103 Master Cylinder Fluid Level Sensor
Fig. 104 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 105 Primary And Secondary Brake Tubes With
ABS Brakes
PLBRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)

VACUUM BOOSTER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, with engine not
running, pump the brake pedal until a firm pedal is
achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector from
brake fluid level sensor located in master cylinder
brake fluid reservoir (Fig. 114).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 115) and (Fig.
116). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner such as Mopar Brake Parts
Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 117) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 118) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 118) located in the front of the power
Fig. 114 Master Cylinder Fluid Level Sensor
Fig. 115 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 116 Primary And Secondary Brake Tubes With
ABS Brakes
Fig. 117 Master Cylinder Mounting To Vacuum
Booster
5 - 44 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

If old brake shoe return or hold down springs have
overheated or are damaged, replace. Overheating
indications are paint discoloration or distorted end
coils.
REAR DRUM BRAKE WHEEL CYLINDER
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
CHASSIS TUBES AND HOSES
Flexible rubber hose is used at both front and rear
brakes. Inspection of brake hoses should be per-
formed whenever the brake system is serviced and
every 7,500 miles or 12 months, whichever comes
first (every engine oil change). Inspect hydraulic
brake hoses for severe surface cracking, scuffing,
worn spots or physical damage. If the fabric casing of
the rubber hose becomes exposed due to cracks or
abrasions in the rubber hose cover, the hose should
be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure.
Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.
The steel brake tubing should be inspected periodi-
cally for evidence of corrosion, physical damage or con-
tact with moving or hot components of the vehicle.
REAR WHEEL HUB AND BEARING ASSEMBLY
The rear hub and bearing assembly is designed for
the life of the vehicle and should require no mainte-
nance. The following procedure may be used for eval-
uation of bearing condition.
With wheel and brake drum removed, rotate
flanged outer ring of hub. Excessive roughness, lat-
eral play or resistance to rotation may indicate dirt
intrusion or bearing failure. If the rear wheel bear-
ings exhibit these conditions during inspection, the
hub and bearing assembly should be replaced.Damaged bearing seals and resulting excessive
grease loss may also require bearing replacement.
Moderate grease loss from bearing is considered nor-
mal and should not require replacement of the hub
and bearing assembly.
ADJUSTMENTS
STOP LAMP SWITCH
(1) Remove stop lamp switch from its bracket by
rotating it approximately 30É in a counter-clockwise
direction.
(2) Disconnect wiring harness connector from stop
lamp switch.
(3) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(4) Install the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp
switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting
bracket. When switch is fully installed in the square
hole of the bracket, rotate switch clockwise approxi-
mately 30É to lock the switch into the bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If too much force is used, damage to the vacuum
booster, stop lamp switch or striker (Fig. 185) can
result.
(5) Connect the wiring harness connector to the
stop lamp switch.
(6) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger
(Fig. 185) to ratchet backward to the correct position.
REAR DRUM BRAKE SHOE ADJUSTMENT
NOTE: Normally, self adjusting drum brakes will
not require manual brake shoe adjustment.
Although in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
(1) Raise the vehicle so all wheels are free to turn.
See Hoisting Recommendations in the Lubrication
And Maintenance Section at the front of this service
manual.
(2) Remove rear brake adjusting hole rubber plug
(Fig. 186) from the rear brake shoe support plate.
Fig. 184 Adjuster Screw And Lever (Typical)
PLBRAKES 5 - 65
CLEANING AND INSPECTION (Continued)

(3) Remove the rubber plug from the adjusting
hole in the brake shoe backing plate on both sides of
the vehicle.
(4)Driver (left) side park brake shoe adjust-
ment procedure.Insert a medium size screwdriver
through adjustment hole in backing plate. Position
the srewdriver against the starwheel on the park
brake shoe adjuster mechanism. Using the screw-
driver rotate the starwheeldownwarduntil a slight
drag is felt when turning the rear tire and wheel.
Then, using the screwdriver rotate the starwheel
upwardjust until the rear tire and wheel can be
rotated with no park brake shoe drag. From the
point where there is no more park brake drag rotate
the starwheelupwarda maximum of two additional
clicks. The park brake shoe to drum clearance is
know properly adjusted.
(5)Passenger (right) side park brake shoe
adjustment procedure.Insert a medium size
screwdriver through adjustment hole in backing
plate. Position the srewdriver against the starwheel
on the park brake shoe adjuster mechanism. Using
the screwdriver rotate the starwheelupwarduntil a
slight drag is felt when turning the rear tire and
wheel. Then, using the screwdriver rotate the star-
wheeldownwardjust until the rear tire and wheel
can be rotated with no park brake shoe drag. From
the point where there is no more park brake drag
rotate the starwheeldownwarda maximum of two
additional clicks. The park brake shoe to drum clear-
ance is know properly adjusted.
(6) Install the rubber plug in the adjusting hole on
the brake shoe backing plate on both sides of the
vehicle.
(7) Lower vehicle far enough to allow access the
park brake lever. The rear tires must not be on the
ground.
(8) Fully apply and release the park brakes two
times after adjusting the park brake shoes. Then
rotate both rear wheels to ensure that the park
brake shoes do not drag on the brake drum following
the application and release of the park brakes.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. Anopen container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
MASTER CYLINDER ASSEMBLY:
Type ...........................Dual Tandem
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE / STROKE
AND SPLIT:
NonABS ....21mmx32.6 mm (.875 in. x 1.28 in.)
ABS........21mmx32.7 mm (.874 in. x 1.29 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
ABS ..........Primary 3/8±24 Secondary 7/16±24
Non ABS . . .Primary Inboard And Outboard 7/16±24
Non ABS . . .Secondary Inboard And Outboard 3/8±23
Outlet Fitting Type.......SAE 45 É Inverted Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type.SAE 45 É Inverted Flare
BOOSTER:
Make/Type.........Bendix Vacuum W/&W/O ABS
Mounting Studs.....................M8x1.25
Type ..........................230 mm Single
Boost At 20 inches Of Manifold Vacuum. . . .4690 All
PROPORTIONING VALVE:
Material...........................Aluminum
Function........Hydraulic Pressure Proportioning
BRAKE PEDAL
Pedal Ratio.............................3.28
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To
HCU At HCU Ports........21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
PLBRAKES 5 - 67
ADJUSTMENTS (Continued)