1999 DODGE NEON air conditioning

(8) Disconnect throttle body linkage.
(9) Disconnect engine wiring harness.
(10) Disconnect heater hoses.
(11) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(12) Hoist vehicle and remove right inner splash
shield (Fig. 15).
(13) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(14) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(15) Disconnect exhaust pipe from manifold.
(16) Remove front engine mount.
(17) Manual transmission: Remove power hop
damper.
(18) Lower vehicle. Remove air cleaner assembly.
(19) Remove power steering pump and reservoir,
Set them aside.
(20) Remove A/C compressor.
(21) Remove ground straps to body.
(22) Raise vehicle enough to allow engine dolly
and cradle Special Tools 6135 and 6710 to be
installed under vehicle.
(23) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 16). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(24) Install safety straps around the engine to cra-
dle tighten; straps and lock them into position.(25) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(26) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(27) Remove engine and transmission mount thru-
bolts.
(28) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the cra-
dle to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Remove safety straps from engine and trans-
mission assembly. Slowly raise vehicle enough to
remove the engine dolly and cradle.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
Fig. 15 Right Inner Splash Shield
Fig. 16 Positioning Engine Cradle Support Post
Mounts
9 - 20 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Remove air cleaner inlet duct (Fig. 17)
(2) Remove ignition coil pack (Fig. 18).
(3) Remove the cylinder head cover bolts.
(4) Remove cylinder head cover from cylinder
head.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new cylinder head cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install cover assembly to head and tighten fas-
teners to 12 N´m (105 in. lbs.).
(3) Install ignition coil pack. Tighten fasteners to
23 N´m (200 in. lbs.).
SPARK PLUG TUBE
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 19). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
Fig. 17 Inlet Duct Removal
Fig. 18 Ignition Coil Pack
PL2.0L SOHC ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)

the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
TIMING BELT TENSIONERÐMECHANICAL
REMOVAL
(1) Remove timing belt. Refer to procedure out-
lined in this section.
(2) Remove tensioner assembly attaching bolts
(Fig. 65).
(3) Remove tensioner assembly.
CAUTION: The timing belt tensioner is serviced as
an assembly. To prevent premature timing belt fail-
ure, DO NOT separate the tensioner pulley from
mounting bracket.
INSTALLATION
(1) Install timing belt tensioner assembly. Tighten
attaching bolts to 28 N´m (250 in. lbs.).
(2) Install timing belt. Refer to procedure outlined
in this section.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove front engine mount bracket. Refer to
Engine MountÐFront, in this section for procedures.
(3) Remove powertrain bending strut.
(4) Remove structural collar from oil pan to tran-
saxle (Fig. 66).
(5) Remove transaxle lower dust cover.
(6) If equipped with air conditioning remove oil fil-
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.(7) Remove oil pan.
(8) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 67).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
Fig. 64 Crankshaft DamperÐInstallationFig. 65 Timing Belt Tensioner AssemblyÐRemoval/
Installation
Fig. 66 Structural CollarÐRemoval and Installation
9 - 36 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

²Step 1: Install the collar to oil pan bolts and
tighten to 3 N´m (30 in. lbs.).
²Step 2: Install collar to transaxle bolts and
tighten to 108 N´m (80 ft. lbs.).
²Step 3: Final torque the collar to oil pan bolts to
54 N´m (40 ft. lbs.).
(2) Lower vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect and remove battery and tray. Set
Powertrain Control Module (PCM) aside.
(3) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(4) Remove upper radiator hose, radiator and fan
module. Refer to Group 7, Cooling System for proce-
dure.
(5) Remove lower radiator hose.
(6) Disconnect automatic transmission cooler lines
and plug. If equipped.
(7) Disconnect clutch cable (Manual) and transmis-
sion shift linkage.
(8) Disconnect throttle body linkage.
(9) Disconnect engine wiring harness.
(10) Disconnect heater hoses.
(11) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(12) Hoist vehicle and remove right inner splash
shield (Fig. 16).
(13) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(14) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(15) Disconnect exhaust pipe from manifold.
(16) Remove front engine mount.
(17) Manual transmission: Remove power hop
damper.
Fig. 14 Power Hop Damper
Fig. 15 Structural CollarÐRemoval and Installation
Fig. 16 Right Inner Splash Shield
PL2.0L DOHC ENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)

(18) Lower vehicle. Remove air cleaner assembly.
(19) Remove power steering pump and reservoir,
Set them aside.
(20) Remove A/C compressor.
(21) Remove ground straps to body.
(22) Raise vehicle enough to allow engine dolly
and cradle Special Tools 6135 and 6710 to be
installed under vehicle.
(23) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 17). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(24) Install safety straps around the engine to cra-
dle tighten; straps and lock them into position.
(25) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(26) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(27) Remove engine and transmission mount thru-
bolts.
(28) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the cra-
dle to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Remove safety straps from engine and trans-
mission assembly. Slowly raise vehicle enough to
remove the engine dolly and cradle.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
Fig. 17 Positioning Engine Cradle Support Post
Mounts
9 - 66 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install timing belt tensioner assembly. Tighten
attaching bolts to 28 N´m (250 in. lbs.).
(2) Install timing belt. Refer to procedure outlined
in this section.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove front engine mount bracket. Refer to
Engine MountÐFront, in this section for procedures.
(3) Remove powertrain bending strut.
(4) Remove structural collar from oil pan to tran-
saxle (Fig. 59).
(5) Remove transaxle lower dust cover.
(6) If equipped with air conditioning, remove oil
filter and adaptor. Refer to Oil Filter Adapter
Removal and Installation in this section.
(7) Remove oil pan.
(8) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 60).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
(4) Install oil filter and adaptor.
(5) Install transaxle lower dust cover.
(6) Install powertrain bending strut.
(7) Install front engine mount and bracket.CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(8) Install the structural collar (Fig. 59) using the
following 3 step torque sequence:
²Step 1: Install the collar to oil pan bolts and
tighten to 3 N´m (30 in. lbs.).
²Step 2: Install collar to transaxle bolts and
tighten to 108 N´m (80 ft. lbs.).
²Step 3: Final torque the collar to oil pan bolts to
54 N´m (40 ft. lbs.).
(9) Fill engine crankcase with proper oil to correct
level.
CAMSHAFT OIL SEALS
REMOVAL
(1) Remove front timing belt cover, timing belt,
and timing belt tensioner. Refer to procedure out-
lined in this section.
CAUTION: Before removing timing belt set crank-
shaft sprocket 3 notches before TDC, this will pre-
vent possible engine damage (Fig. 61).
Fig. 59 Structural CollarÐRemoval and Installation
Fig. 60 Oil Pan Sealing
Fig. 61 Crankshaft Sprocket 3 Notches Before TDC
PL2.0L DOHC ENGINE 9 - 81
REMOVAL AND INSTALLATION (Continued)

FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 21
MODES OF OPERATION.................. 21
DESCRIPTION AND OPERATION
AIR CONDITIONING CLUTCH RELAYÐ
PCM OUTPUT......................... 31
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT............. 25
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT........................... 25
AUTOMATIC SHUTDOWN RELAYÐ
PCM OUTPUT......................... 32
BATTERY TEMPERATURE SENSORÐ
PCM INPUT........................... 25
BATTERY VOLTAGEÐPCM INPUT........... 25
BRAKE SWITCHÐPCM INPUT.............. 25
CAMSHAFT POSITION SENSORÐPCM INPUT . 25
CHARGING SYSTEM INDICATOR LAMPÐ
PCM OUTPUT......................... 32
CRANKSHAFT POSITION SENSORÐ
PCM INPUT........................... 26
DATA LINK CONNECTOR.................. 33
DUTY CYCLE EVAP PURGE SOLENOIDÐ
PCM OUTPUT......................... 32
ELECTRIC EGR TRANSDUCERÐ
PCM OUTPUT......................... 32
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT........................... 26
FUEL INJECTORSÐPCM OUTPUT.......... 34
FUEL LEVEL SENSORÐPCM INPUT......... 27
FUEL PUMP RELAYÐPCM OUTPUT......... 32
GENERATOR FIELDÐPCM OUTPUT......... 33
HEATED OXYGEN SENSOR (O2S SENSOR)Ð
PCM INPUT........................... 27
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . 33
IGNITION CIRCUIT SENSEÐPCM INPUT..... 28
IGNITION COILÐPCM OUTPUT............. 34
INTAKE AIR TEMPERATURE SENSORÐ
PCM INPUT........................... 28
KNOCK SENSORÐPCM INPUT............. 29
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT.................. 34
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT.................. 29
PARK/NEUTRAL POSITION SWITCHÐ
PCM INPUT........................... 30
POWER DISTRIBUTION CENTER........... 23
POWER STEERING PRESSURE SWITCHÐ
PCM INPUT........................... 30
POWERTRAIN CONTROL MODULE.......... 24SCI RECEIVEÐPCM INPUT................ 30
SCI RECEIVEÐPCM OUTPUT.............. 35
SENSOR RETURNÐPCM INPUT............ 30
SOLID STATE FAN RELAYÐPCM OUTPUT.... 35
SPEED CONTROL SERVOSÐPCM OUTPUT . . . 30
SPEED CONTROLÐPCM INPUT............ 35
SYSTEM DIAGNOSIS..................... 23
TACHOMETERÐPCM OUTPUT............. 35
THROTTLE POSITION SENSORÐPCM INPUT . 30
TORQUE CONVERTOR CLUTCH SOLENOIDÐ
PCM OUTPUT......................... 35
VEHICLE SPEED SENSORÐPCM INPUT..... 30
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS............. 46
CAMSHAFT AND CRANKSHAFT POSITION
SENSOR............................. 47
ENGINE COOLANT TEMPERATURE SENSOR . . 47
HEATED OXYGEN SENSOR............... 47
IDLE AIR CONTROL (IAC) MOTOR TEST...... 47
KNOCK SENSOR........................ 47
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 48
THROTTLE BODY MINIMUM AIR FLOW....... 48
THROTTLE POSITION SENSOR............ 48
VEHICLE SPEED SENSOR................ 49
VISUAL INSPECTIONÐDOHC.............. 40
VISUAL INSPECTIONÐSOHC.............. 35
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT.................. 55
CAMSHAFT POSITION SENSOR............ 54
CRANKSHAFT POSITION SENSOR.......... 54
DOWNSTREAM HEATED OXYGEN SENSOR . . . 55
DUTY CYCLE EVAP PURGE SOLENOID VALVE . 53
ENGINE COOLANT TEMPERATURE SENSOR . . 56
IDLE AIR CONTROL MOTOR............... 52
KNOCK SENSOR........................ 57
MAP/IAT SENSORÐDOHC................. 53
MAP/IAT SENSORÐSOHC................. 53
POWERTRAIN CONTROL MODULE (PCM).... 54
THROTTLE BODYÐAUTOMATIC
TRANSMISSION....................... 50
THROTTLE BODYÐMANUAL TRANSMISSION . 50
THROTTLE POSITION SENSOR (TPS)....... 52
UPSTREAM HEATED OXYGEN SENSOR...... 54
VEHICLE SPEED SENSOR................ 56
SPECIFICATIONS
TORQUE.............................. 57
VECI LABEL............................ 57
SPECIAL TOOLS
FUEL................................. 57
14 - 20 FUEL SYSTEMPL

below the minimum acceptable percentage, the PCM
stores a diagnostic trouble code in memory.
During certain idle conditions, the PCM may enter
a variable idle speed strategy. During variable idle
speed strategy the PCM adjusts engine speed based
on the following inputs.
²A/C sense
²Battery voltage
²Battery temperature
²Engine coolant temperature
²Engine run time
²Power steering pressure switch
²Vehicle mileage
ACCELERATION MODE
This is a CLOSED LOOP mode. The PCM recog-
nizes an abrupt increase in Throttle Position sensor
output voltage or MAP sensor output voltage as a
demand for increased engine output and vehicle
acceleration. The PCM increases injector pulse width
in response to increased fuel demand.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera-
tion the following inputs are received by the PCM:
²A/C pressure transducer
²A/C sense
²Battery voltage
²Intake air temperature
²Engine coolant temperature
²Crankshaft position (engine speed)
²Exhaust gas oxygen content (upstream heated
oxygen sensor)
²Knock sensor
²Manifold absolute pressure
²Power steering pressure switch
²Throttle position
²IAC motor control changes in respones to MAP
sensor feedback
The PCM may receive a closed throttle input from
the Throttle Position Sensor (TPS) when it senses an
abrupt decrease in manifold pressure. This indicates
a hard deceleration. In response, the PCM may
momentarily turn off the injectors. This helps
improve fuel economy, emissions and engine braking.
If decel fuel shutoff is detected, downstream oxy-
gen sensor diagnostics is performed.
WIDE-OPEN-THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the PCM:
²Intake air temperature
²Engine coolant temperature
²Engine speed
²Knock sensor
²Manifold absolute pressure²Throttle position
When the PCM senses a wide-open-throttle condi-
tion through the Throttle Position Sensor (TPS) it de-
energizes the A/C compressor clutch relay. This
disables the air conditioning system.
The PCM does not monitor the heated oxygen sen-
sor inputs during wide-open-throttle operation except
for downstream heated oxygen sensor and both
shorted diagnostics. The PCM adjusts injector pulse
width to supply a predetermined amount of addi-
tional fuel.
IGNITION SWITCH OFF MODE
When the operator turns the ignition switch to the
OFF position, the following occurs:
²All outputs are turned off, unless 02 Heater
Monitor test is being run. Refer to Group 25,
On-Board Diagnostics.
²No inputs are monitored except for the heated
oxygen sensors. The PCM monitors the heating ele-
ments in the oxygen sensors and then shuts down.
DESCRIPTION AND OPERATION
SYSTEM DIAGNOSIS
The PCM can test many of its own input and out-
put circuits. If the PCM senses a fault in a major
system, the PCM stores a Diagnostic Trouble Code
(DTC) in memory.
For DTC information, refer to Group 25, Emission
Control Systems. See On-Board Diagnostics.
POWER DISTRIBUTION CENTER
The power distribution center (PDC) is located next
to the battery (Fig. 1). The PDC contains the starter
relay, radiator fan relay, A/C compressor clutch relay,
auto shutdown relay, fuel pump relay and several
fuses.
Fig. 1 Power Distribution Center (PDC)
PLFUEL SYSTEM 14 - 23
GENERAL INFORMATION (Continued)