1999 DODGE NEON ECU

SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL SQUEAKS
WHEN DEPRESSED TO FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings
CLASH±INTO±REVERSE COMPLAINTS
Some Right Hand Drive NV T350 (A-578) manual
transaxles are equipped with a reverse brake. It pre-
vents 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.
NOTE: Verify that nothing is obstructing pedal
travel. Floormats or other articles located under-
neath the clutch pedal could prevent the clutch
from disengaging fully. Also make sure that the
hydraulic clutch release mechanism is functioning
properly.
(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 MASTER CYLINDER Ð RIGHT HAND
DRIVE (RHD)
The clutch master cylinder and remote reservoir
are serviced as an assembly. The linkage components
and cylinder cannot be overhauled or serviced sepa-
rately.
REMOVAL
(1) Hoist vehicle.
(2) Disconnect quick-connector coupler at lower
hydraulic damper using Special Tool 6638 (Fig. 3).(3) Lower vehicle.
(4) Unsnap hydraulic line from left rail retainer
clips (Fig. 4).
(5) From underneath dash panel, remove cotter
pin from pedal bushing.
(6) Remove pedal pivot pin from master pushrod
assembly and bushing.
NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
removal.
(7) Slide remote reservoir up out of bracket.
Fig. 3 Quick-Connect Coupler
Fig. 4 Routing Clips
6 - 6 CLUTCHPL
DIAGNOSIS AND TESTING (Continued)

(8) Grasp clutch master cylinder and turn 1/4 turn
counterclockwise (Fig. 5).
(9) Remove cylinder from dash panel.
INSTALLATION
NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
installation.
(1) Position clutch master cylinder to dash panel
approximately 45É counterclockwise. (Fig. 6).
(2) Position master cylinder push rod so that
retention fingers are facing towards the right side of
the vehicle.
(3) Insert push rod through dash panel hole and
slide push rod eye between the clutch pedal and loca-
tor bracket.
(4) Rotate cylinder 1/4 turn clockwise.
(5) Slide remote reservoir into bracket at dash
panel until locked in.(6) From underneath dash panel, ensure clutch
master cylinder push rod is located between the
pedal and locator bracket. Snap clutch pedal pin into
pushrod and slide cotter pin into bushing.
(7) Route hydraulic lines to retaining clips at
frame rail.
(8) Raise vehicle.
(9) Connect upper clutch hydraulic line from mas-
ter cylinder (quick±connect) to lower clutch hydraulic
line near damper.
(10) Check the operation of the hydraulic clutch
release system.
(11) Actuate clutch pedal rapidly 20±30 times.
Check for leaks
HYDRAULIC SLAVE CYLINDER Ð RIGHT HAND
DRIVE (RHD)
REMOVAL
(1) Raise vehicle on hoist.
(2) Separate hydraulic line at quick-disconnect
using Special Tool 6638. (Fig. 7).
(3) Remove nuts retaining hydraulic damper to
transaxle (Fig. 8).
(4) Remove engine mount bracket.
(5) Disconnect ground wire from starter.
(6) Remove two bolts retaining hydraulic slave cyl-
inder to transaxle (Fig. 8).
(7) Remove slave cylinder from transmission.
INSTALLATION
CAUTION: When reinstalling starter wiring, make
certain wiring does not contact hydraulic tubing.
(1) To install, reverse above procedure.
(2) Actuate clutch pedal 20±30 times. Check for
leaks.
Fig. 5 Hydraulic Clutch Master Cylinder
Fig. 6 Master Cylinder at Dash PanelFig. 7 Hydraulic Line
PLCLUTCH 6 - 7
REMOVAL AND INSTALLATION (Continued)

SELECTION AND ADDITIVES
The use of aluminum cylinder heads, intake mani-
folds DOHC, and water pumps requires special corro-
sion protection. MopartAntifreeze or the equivalent
is recommended for best engine cooling without cor-
rosion. When mixed only to a freeze point of -37ÉC
(-35ÉF) to -59ÉC (-50ÉF). If it looses color or becomes
contaminated, drain, flush, and replace with fresh
properly mixed solution.
COOLING SYSTEM PRESSURE CAP
The cooling system is equipped with a pressure cap
that releases built up pressure, maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is a vent valve in the center of the cap that
allows a small coolant flow from the coolant reserve
system (CRS) tank. This valve is spring loaded in the
closed position. However it must be free to open dur-
ing system cool-down.If the valve is stuck shut,
the radiator hoses will collapse on cool-down.
Clean the vent valve (Fig. 7) to ensure proper
sealing function.
There is a gasket in the cap that seals to the top of
the filler neck so that vacuum is maintained to draw
coolant back into the system from the coolant reserve
system (CRS) tank.
RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A
SHOP TOWEL OVER THE CAP AND WITHOUT
PUSHING DOWN ROTATE IT COUNTERCLOCKWISE
TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE
SYSTEM STOPS PUSHING OUT COOLANT AND
STEAM AND THE PRESSURE DROPS CONTINUE
SERVICE.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAM. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter.The hose clamps are removed by using Special Tool
6094 or equivalent constant tension clamp pliers
(Fig. 8) to compress hose clamp.
A hardened, cracked, swollen or restricted hose
should be replaced. Do not damage radiator inlet and
outlet when loosening hoses.
Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.
Spring type hose clamps are used in all applica-
tions. If replacement is necessary replace with the
original Mopartequipment spring type clamp.
ENGINE BLOCK HEATER
The heater is mounted in a core hole (in place of a
core hole plug) in the engine block, with the heating
element immersed in coolant.The power cord
must be secured in its retainer clips, and not
positioned so it could contact linkages or
exhaust manifolds and become damaged.
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
Fig. 7 Cooling System Pressure Cap
PLCOOLING 7 - 5
DESCRIPTION AND OPERATION (Continued)

COOLING SYSTEMÐREFILLING
First clean system to remove old glycol, see Cooling
System Cleaning.
Fill system using antifreeze described in Coolant
section. Fill 50 percent of capacity with 100 percent
glycol. Then complete filling system with water.
Continue filling system until full, this provides bet-
ter heater performance.Be careful not to spill
coolant on drive belts or the generator.
Fill coolant reserve system to at least the FULL
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank after three or four warm-
up/cool down cycles to maintain coolant level between
the FULL and ADD marks; if any trapped air was
removed from the system.
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL
(1) Raise vehicle on a hoist. Remove right inner
splash shield.
(2) Remove accessory drive belts and power steer-
ing pump. Refer to Accessory Drive Belt service in
this section.
(3) Drain cooling system. Refer to Cooling System
Draining in this section.
(4) Support engine from the bottom and remove
right engine mount.
(5) Remove power steering pump bracket bolts and
set pump and bracket assembly aside. Power steering
lines do not need to be disconnected.
(6) Remove right engine mount bracket.
(7) Remove timing belt and timing belt tensioner.
Refer to Group 9, Engine for procedure.
(8) Remove camshaft sprockets and inner timing
belt cover. Refer to Group 9, Engine for procedure.(9) Remove water pump attaching screws to engine
(Fig. 14).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 15). Use small dabs of Mopart
Silicone Rubber Adhesive Sealant around the water
pump body to secure O-ring in place during installa-
tion.
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring and cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install inner timing belt cover.
(5) Install timing belt. Refer to Group 9, Engine
for procedures.
(6) Install right engine mount bracket and engine
mount. Refer to Group 9, Engine for procedure.
(7) Fill cooling system. SeeCooling System
Refilling.
(8) Install power steering pump and accessory
drive belts, Refer to Accessory Drive Belts, in this
section.Fig. 13 Draining Cooling System
Fig. 14 Water Pump
Fig. 15 Water Pump Body
PLCOOLING 7 - 17
SERVICE PROCEDURES (Continued)

must be replaced withonlythe recommended part
for adequate strength, performance and safety.
(1) To remove fan from motor shaft, bench support
the motor and motor shaft, while removing the fan
retaining clip, so that the shaft and motor will not be
damaged by excessive force.Surface burr removal
may be required to remove fan from motor
shaft (Fig. 25).Do not permit the fan blades to
touch the bench.
(2) To install fan on motor shaft, slide the fan over
shaft. Support motor and shaft as above while
installing fan retaining clip.
INSTALLATION FAN MODULE
(1) Install module to radiator. Torque shroud to
radiator fasteners to 7.5 N´m (65 in. lbs.).
(2) Connect fan motor lead.For wiring diagrams
of fan motor systems Refer to 8W Wiring Dia-
grams.
ELECTRIC FAN MOTORÐSERVICE
WARNING: Do not disassemble the fan motor from
the support bracket.
Electric fan motor is serviced as an assembly with
the fan module.
FAN SHROUD
Some fan shrouds are equipped with flapped doors
to prevent the shroud from restricting air flow at
high speeds.
All vehicles have fan shrouds to improve fan air
flow efficiency.
The shroud supports the electric fan motor and
fan. For removal and installation procedures, refer to
radiator removal in this Section.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and
Refill of this section for procedure.
(2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
ACCESSORY DRIVE BELTS
AIR CONDITIONING COMPRESSOR AND
POWER STEERING PUMP
(1) Loosen the power steering pump locking bolts
A and B and pivot bolt C (Fig. 26) to remove and
install belt and/or adjust belt tension.
(2) Using a 1/2º breaker bar, adjust belt tension by
applying torque to the square D hole on the power
steering pivot bracket. Adjust tension to specification
given in Belt Tension Chart.
(3) Tighten in order, first tighten locking bolt A to
27 N´m (20 ft. lbs.) then, bolt B to 27 N´m (20 ft. lbs.)
Then pivot bolt C to 54 N´m (40 ft. lbs.).
GENERATOR BELT
(1) Loosen pivot bolt E then locking nut F and
adjusting bolt G (Fig. 27) to remove and install belt
and/or adjust belt tension.
(2) Tighten adjusting bolt G, adjust belt tension to
specification shown in Belt Tension Chart.
(3) Tighten pivot bolt E to 54 N´m (40 ft. lbs.).
Locking nut F to 54 N´m (40 ft. lbs.).
CLEANING AND INSPECTION
WATER PUMP
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
Fig. 25 Servicing Radiator Fan
PLCOOLING 7 - 21
REMOVAL AND INSTALLATION (Continued)

(2) Install battery hold down clamp, making sure
that it is properly positioned on battery.
(3) Place thermoguard cover over the battery and
snap it together with battery tray (Fig. 17). The bat-
tery tray pencil strut may have to be loosened on one
end to install the thermoguard cover. After the ther-
moguard cover is in place, tighten pencil strut as
necessary.(4) Connect battery cable clamps to battery posts
and making sure top of clamp is flush or below with
top of post (Fig. 18). Install battery positive cable
first.
(5) Tighten clamp nuts securely.
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to Battery Removal.
(2) Remove battery tray pencil strut. Remove bat-
tery tray, refer to (Fig. 17).
INSTALLATION
For installation reverse above procedures.
FRESH AIR INLET TUBE REMOVAL
REMOVAL
(1) Ensure that the ignition switch and all acces-
sories are OFF
(2) Remove battery negative cable first then the
positive cable (Fig. 4).
(3) Remove battery thermoguard cover (Fig. 15).
Fig. 15 Battery Thermoguard
Fig. 16 Battery Hold-Down
Fig. 17 Battery Tray Removal
Fig. 18 Remove and Install Battery Cables
PLBATTERY 8A - 9
REMOVAL AND INSTALLATION (Continued)

GLOVE BOX SWITCH/LAMP
REMOVAL
(1) Disconnect battery negative cable and isolate it
or remove fuse 12 prior to removing the switch, or
wires may short to ground.
(2) Open the glove box and push the glove box
sides inward allowing the door bumpers to clear and
the box to tip rearward.
(3) Reach inside the opening and squeeze the
lamp/switch retainers until they are disengage.
(4) Pull the switch/lamp rearward and remove it.
Replace the lamp. To replace the switch disconnect
wire and replace the switch.
INSTALLATION
For installation, reverse the above procedures.
HEADLAMP SWITCH
REMOVAL
(1) Remove the steering column cover and liner.
(2) Remove the three screws securing headlamp
switch mounting plate to the instrument panel (Fig.
17).
(3) Pull the headlamp switch and mounting plate
rearward from the instrument panel opening.
(4) Disconnect both the nine way and the ground
wiring connectors from the switch.
(5) Remove the switch knob by depressing the
release button on the bottom on the switch and pull-
ing out knob from switch.
(6) Snap headlamp switch bezel out of mounting
plate to gain access to the mounting plate retaining
nut.
(7) Remove the headlamp switch, mounting plate
retaining nut and separate switch from mounting
plate.
INSTALLATION
For installation, reverse the above procedures.
HEATER A/C CONTROL
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick (special tool #C-4755), gently
pry up on the top cover and cluster bezel to remove
(Fig. 19).
(3) Open the ash receiver.
(4) Using a trim stick (special tool #C-4755), gently
pry out on the center bezel and remove.
(5) Remove the six attaching screws across the for-
ward portion of the right upper trim panel. Then pull
the panel rearward to disengage the three locator
pins and remove.(6) Reach in and disconnect the wiring connector(s)
for the rear window defogger and/or fog lamp
switch(s) as required.
(7) If equipped with RKE, remove the two screws
retaining the module and lay over the instrument
cluster.
(8) Gently pull on the center A/C outlet duct to
remove.
(9) Remove three attaching screws at corners of
the control (Fig. 18), two front retaining and one
retaining from the top rear.
(10) Pull the control rearward and disconnect the
wiring connector.
(11) Using a screwdriver, disengage the cable
attachment clips.
INSTALLATION
For installation, reverse the above procedures.
Fig. 17 Headlamp Switch
Fig. 18 Heater A/C Control
PLINSTRUMENT PANEL AND SYSTEMS 8E - 9
REMOVAL AND INSTALLATION (Continued)

AUDIO SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION.............. 1
DIAGNOSIS AND TESTING
ANTENNA.............................. 3
AUDIO DIAGNOSTIC TEST PROCEDURES..... 1BENCH TEST FOR ANTENNA MALFUNCTION . . 3
REMOVAL AND INSTALLATION
ANTENNA.............................. 3
FRONT DOOR SPEAKER................... 4
INSTRUMENT PANEL SPEAKER............. 4
RADIO................................. 4
REAR SHELF SPEAKER(S)................. 5
GENERAL INFORMATION
INTRODUCTION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with the vehicle.
The vehicles are equipped with an Interior (Igni-
tion Off Draw) fuse in the Power Distribution Center
located in the engine compartment. After the Interior
(IOD) fuse or battery has been disconnected the clock
will require resetting.
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION
The radio utilizes a ground wire plugged on to a
blade terminal and is bolted to the radio chassis.
Both connector and terminal should be securely
attached. The engine has three separate ground
straps to suppress ignition noise which may interfere
with radio reception.
²Left engine mount clip on strap
²Engine to shock tower reinforcement
²Rear strut to body, clip-on strap
Inductive type spark plug cables in the high ten-
sion circuit of the ignition system complete the inter-
ference suppression. Faulty or deteriorated spark
plug wires should be replaced.
In addition, there is a capacitor mounted on the
cylinder head which also helps suppress ignition
noise.
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES
CAUTION: The CD player will only operate between
approximate temperatures of -23ÉC and +65ÉC (-10ÉF
and +145ÉF).
Whenever a radio malfunction occurs;
(1) First check FUSES:
(a) Power Distribution Center (PDC), Interior
lamp fuse, M1 - Radio Memory Feed
(b) Fuse Block:
(I) Fuse 12, Illumination in the fuse block
(II) Fuse 16, Ignition feed in the fuse block
NOTE: The vehicles are shipped with the INTERIOR
LAMP fuse disconnected.
(2) Verify, the radio wire harness are properly con-
nected before starting normal diagnosis and repair
procedures. Refer to Audio Diagnosis table and/or
Group 8W, Wiring Diagrams, Radio Section.
PLAUDIO SYSTEM 8F - 1