1999 DODGE NEON engine oil

The clutch cable has a unique self-adjuster mecha-
nism built into the cable which compensates for
clutch disc wear. The cable requires no maintenance
or lubrication. There are no serviceable components
on the cable assembly.
The clutch pedal is connected to the cable through
a plastic spacer. The upper end of the clutch pedal
pivots in the pedal bracket on two nylon bushings
and a shaft. These bushings are greased at assembly
and do not require periodic lubrication.
CLUTCH DISC AND COVER APPLICATION
The 2.0 single overhead cam engine uses a 216 mm
(8.5 in.) clutch disc. The manual transaxle is avail-
able only with the 2.0 liter engine.
CLUTCH REPLACEMENT
The transaxle must be removed to service the
clutch disc, pressure plate, flywheel/drive plate,
and/or clutch release bearing and lever.
DESCRIPTION AND OPERATION
CLUTCH CABLE
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear. This adjuster mechanism is located
within the clutch cable assembly. The preload spring
maintains tension on the cable. This tension keeps
the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 1).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
the switch is in its normal (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050), the ohmmeter should show continuity (zero
ohms).
If ohmmeter readings do not fall within these
ranges, the switch is defective, and must be replaced.
SERVICE DIAGNOSIS±CLUTCH PEDAL POSITION SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WON'T CRANK
WHEN CLUTCH PEDAL IS
PRESSED TO THE FLOORSwitch does not have continuity
when plunger is depressed 1.25
mmDefective switch. Replace switch.
Switch plunger is not depressed
when clutch pedal is pushed to the
floorFloor mat interferes with clutch pedal
movement. Move floor mat out of the way.
Problem is related to other
components in the starting circuitCheck other components in the starting
circuit. Refer to Section 8A, Battery/Starting/
Charging System.
Fig. 1 Clutch Pedal Position Switch and
Components
6 - 2 CLUTCHPL
GENERAL INFORMATION (Continued)

CLUTCH PEDAL POSITION
SWITCH±MECHANICAL TEST
With the park brake set and the vehicleIN NEU-
TRAL,turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is
defective (shorted out) and must be replaced. If the
vehicle does not crank, proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.
With the park brake set and the vehicleIN GEAR,
turn the key to the start position and hold it there.
Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there
is no motion, the switch is working properly.
If motion is felt, check to see if the switch is mak-
ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch orthe self-adjusting cable (See ªClutch Will Not Disen-
gage Properlyº). If this condition is not met, then the
switch mounting tab on the brake bracket is bent,
and the brake bracket must be replaced.
If vehicle will not crank, even with clutch pedal
pressed to the floor, refer to ªService Diagnosis-
Clutch Pedal Position Switchº chart in this section.
CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road
test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSISÐCLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft sealCorrect leak and replace w/modular clutch
assembly
Too much grease applied to splines
of disc and input shaftApply lighter coating of grease to splines
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline componentFurther diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly)Replace w/modular clutch assembly
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for damage.
Correct as necessary.
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
CLUTCH COVER AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further. If
chatter persists:
(2) Check to see if clutch cable routing is correct
and operates smoothly.
(3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary.
CLASH±INTO±REVERSE COMPLAINTS
Certain NV T350 (A-578) manual transaxles are
equipped with a reverse brake. It prevents clash
when shifting into reverse, but only if the vehicle is
not moving. See Group 21, Transaxle for further
diagnosis.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.
(2) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(3) Check the input shaft spline, clutch disc
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check for broken clutch cover diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.
REMOVAL AND INSTALLATION
CLUTCH CABLE
REMOVAL
(1) Pull up and remove Power Distribution Center.
(2) Remove clutch cable inspection cover.
(3) Pull back on clutch cable housing and disen-
gage cable from housing (Fig. 2).
Fig. 2 Cable at Transaxle
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

REMOVAL
(1) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(2) Mark clutch cover and flywheel, to maintain
their same relative positions when installing clutch
assembly.
(3) Insert Clutch Disc Aligning Tool 6724 through
the clutch disc hub to prevent the clutch disc from
falling and damaging the facings (Fig. 4).
(4) Loosen clutch cover attaching bolts, one or two
turns at a time, in a crisscross pattern. This will
release spring pressure evenly and avoid cover dam-
age.
CAUTION: Do not touch the clutch disc facing with
oily or dirty hands. Oil or dirt transferred from your
hands onto the clutch disc facing may cause clutch
chatter.
(5) Remove the clutch pressure plate and cover
assembly and disc from flywheel. Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
(2) The friction faces of the flywheel and pressure
plate should not have excessive discoloration, burned
areas, cracks, deep grooves, or ridges. Replace parts
as required.
(3) Clean the flywheel face with medium sandpa-
per (80-180 grade), then wipe the surface with min-
eral spirits. If the surface is severely scored, heat
checked, cracked or warped, replace the flywheel.CAUTION: Do not flat-machine the flywheel face.
The surface profile is tapered.
(4) The heavy side of the flywheel is indicated by a
daub of white paint near the outside diameter. To
minimizethe effects of flywheel unbalance, perform
the following installation procedure:
²Loose assemble the flywheel to the crankshaft.
Use new flywheel attaching bolts which have sealant
on the threads. If new bolts are not available, apply
Loctite sealant to the threads of the original bolts.
This sealant is required to prevent engine oil leak-
age.
²Rotate the flywheel and crankshaft until the
daub of white paint (heavy side) is at the 12 o'clock
position.
²Torque flywheel attaching bolts to 95 N´m (70 ft.
lbs.). Use a crisscross pattern when tightening bolts.
(5) The disc assembly should be handled without
touching the facings. Replace disc if the facings show
evidence of grease or oil soakage, or wear to within
less than .20 mm (.008 inch) of the rivet heads. The
splines on the disc hub and transaxle input shaft
should be a snug fit without signs of excessive wear.
Metallic portions of disc assembly should be dry,
clean, and not discolored from excessive heat. Each of
the arched springs between the facings should not be
broken and all rivets should be tight.
(6) Wipe the friction surface of the pressure plate
with mineral spirits.
(7) Using a straight edge, check pressure plate for
flatness. The pressure plate friction area should be
FLAT TO SLIGHTLY CONCAVE, with the inner
diameter 0.000 mm to 0.1 mm (0.000 in. to 0.0039
in.) below the outer diameter. It should also be free
from discoloration, burned areas, cracks, grooves, or
ridges.
(8) Using a surface plate, test cover for flatness.
All sections around attaching bolt holes should be in
contact with surface plate within .015 inch.
(9) The cover should be a snug fit on flywheel dow-
els. If the clutch assembly does not meet these
requirements, it should be replaced.
INSTALLATION
(1) Mount clutch assembly on flywheel with disc
centered with tool 6724, being careful to properly
align dowels and the alignment marks made before
removal. The flywheel side of the clutch disc is
marked for proper installation. If new clutch or fly-
wheel is installed, align orange cover balance spot as
close as possible to orange flywheel balance spot.
Apply pressure to the alignment tool. Center the tip
of the tool into the crankshaft and the sliding cone
into the clutch fingers. Tighten the clutch attaching
bolts sufficiently to hold the disc in position (Fig. 5).
Fig. 4 Clutch Disc Aligning Tool
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(2) To avoid distortion of the clutch cover, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 28 N´m (250 in. lbs.) following a crisscross
pattern sequence. Remove clutch disc alignment tool.
(3) Install transaxle. See Group 21, Manual Tran-
saxle for procedures.
BELVIDERE BUILT VEHICLES
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
(3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
(5) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(6) The transaxle and modular clutch come out as
an assembly.
(7) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 6). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
(3) To avoid distortion of the drive plate, bolts
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten
bolts to 75 N´m (55 ft. lbs.) following a crisscross pat-
tern sequence.
(4) Install clutch inspection cover.
(5) Install transaxle lower support brackets.
(6) Install starter assembly.
RELEASE BEARING AND FORK
Remove the transaxle from the vehicle. See Group
21, Transaxle for removal and installation proce-
dures.
REMOVAL
(1) Move the lever and bearing assembly to a ver-
tical in-line position. Grasp the release lever with
two hands in the pivot stud socket area. Pull with
even pressure and the lever will pop off the pivot-
±stud. Do not use a screwdriver or pry bar to pop off
the lever. This may damage the spring clip on the
lever.
(2) As a unit, remove the fork from the bearing
thrust plate. Be careful not to damage retention tabs
on bearing.
(3) Examine the condition of the bearing.It is
pre-lubricated and sealed and should not be
immersed in oil or solvent.
(4) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(5) Check the condition of the pivot stud spring
clips on back side of clutch fork. If the clips are bro-
ken or distorted, replace the clutch fork.
Fig. 6 Clutch ComponentsFig. 5 Clutch Installation
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

SERVICE DIAGNOSISÐCLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft sealCorrect leak and replace w/modular
clutch assembly
Too much grease applied to splines
of disc and input shaftApply lighter coating of grease to
splines
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline componentFurther diagnosis required. Check
engine/transmission mounts,
suspension attaching parts and other
driveline components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT OF
CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly)Replace w/modular clutch assembly
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of
flywheel, disc, or cover. Check clutch
housing to engine dowels and dowel
holes for damage. Correct as
necessary.
PLCLUTCH 6 - 3
DIAGNOSIS AND TESTING (Continued)

CLUTCH PEDAL POSITION SWITCH Ð RIGHT
HAND DRIVE (RHD)
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 9).
REMOVAL
(1) Disconnect electrical harness to switch connec-
tor.
(2) Depress wing tabs on switch and push switch
out of mounting bracket. Then slide wires through
slot in bracket.
INSTALLATION
(1) Slide switch wires through slot in switch
bracket.
(2) Line up switch tab with slot in switch bracket
and push switch into position. Do not pull on theswitch wires to seat switch into bracket, switch dam-
age may occur.
(3) Attach switch wiring harness to vehicle wiring
harness.
(4) After installation, the switch must be checked
for proper operation. Refer to Diagnosis and Testing
section for proper testing procedures.
CLUTCH ASSEMBLY Ð RIGHT HAND DRIVE (RHD)
The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.
REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
(3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
(5) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure.
(6) The transaxle and modular clutch come out as
an assembly.
(7) Remove the modular clutch assembly from the
transaxle input shaft (Fig. 10). Handle carefully to
avoid contaminating the friction surfaces.
INSPECTION
(1) Inspect for oil leakage through engine rear
main bearing oil seal and transaxle input shaft seal.
If leakage is noted, it should be corrected at this
time.
INSTALLATION
(1) Mount modular clutch assembly onto input
shaft.
(2) Install transaxle. See Group 21, Manual Tran-
saxle, for procedure.
NOTE: Use new bolts when mounting modular
clutch assembly to drive plate.
Fig. 8 Damper and Slave Cylinder
Fig. 9 Clutch Pedal Position Switch and
ComponentsFig. 10 Clutch Components
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

COOLING
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS................ 2
AUTOMATIC TRANSMISSION OIL COOLER.... 3
COOLANT RECOVERY SYSTEM (CRS)....... 2
COOLANT.............................. 3
COOLING SYSTEM PRESSURE CAP......... 3
COOLING SYSTEM....................... 1
ENGINE BLOCK HEATER.................. 3
ENGINE THERMOSTAT.................... 3
RADIATOR............................. 3
WATER PUMP.......................... 3
DESCRIPTION AND OPERATION
COOLANT PERFORMANCE................. 4
COOLING SYSTEM PRESSURE CAP......... 5
ENGINE BLOCK HEATER.................. 5
ENGINE THERMOSTAT.................... 4
RADIATOR HOSES AND CLAMPS........... 5
WATER PUMP.......................... 6
DIAGNOSIS AND TESTING
ACCESSORY DRIVEBELT DIAGNOSIS....... 13
COOLING SYSTEM DIAGNOSIS............. 7
COOLING SYSTEM FLOW CHECK.......... 14
DEAERATION.......................... 15
ELECTRIC FAN MOTOR TEST.............. 14
ENGINE THERMOSTAT TESTING........... 13
LOW COOLANT LEVEL AERATION.......... 15
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK.............. 15
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP...................... 15
RADIATOR FAN CONTROL................ 14
TEMPERATURE GAUGE INDICATION........ 16
TESTING COOLING SYSTEM FOR LEAKS.... 14WATER PUMP DIAGNOSIS............... 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE........ 16
COOLANT LEVELÐSERVICING............ 16
COOLANTÐADDING ADDITIONAL......... 16
COOLING SYSTEMÐDRAINING............ 16
COOLING SYSTEMÐREFILLING........... 17
REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELTS............... 21
ENGINE BLOCK HEATER................. 21
ENGINE THERMOSTAT................... 18
RADIATOR DRAINCOCK.................. 20
RADIATOR FANS AND MOTOR............ 20
RADIATOR............................ 19
WATER PUMP INLET TUBE............... 18
WATER PUMP......................... 17
CLEANING AND INSPECTION
ACCESSORY DRIVE BELT INSPECTION...... 22
CHEMICAL CLEANING................... 23
CLEANING COOLING SYSTEM............. 22
COOLING SYSTEM CAP.................. 22
RADIATOR FLUSHING................... 23
REVERSE FLUSHING.................... 23
WATER PUMP......................... 21
ADJUSTMENTS
BELT TENSION GAUGE METHOD........... 24
PROPER BELT TENSION................. 23
SPECIFICATIONS
COOLING SYSTEM CAPACITY............. 24
TORQUE.............................. 24
SPECIAL TOOLS
COOLING............................. 24
GENERAL INFORMATION
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, and a water pump to
circulate the coolant. The engine cooling module may
consist of a radiator, electric fan motor, fan, shroud,
coolant reserve system, transmission oil cooler, hoses,
clamps, air condition condenser and transmission oil lines.
²When the Engine is cold: The thermostat is
closed; the cooling system has no flow through the
radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open;
the cooling system has flow through radiator, engine,
heater system and bypass.
Coolant flow circuit for the 2.0L engine is shown in
(Fig. 1).
PLCOOLING 7 - 1