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Page 606 of 1200

DODGE NEON 1999 Service Repair Manual 1
K4
20
BK/LBK4
20
BK/LBK4
18
BK/LB
10C161
K4
20
BK/LB
POWERTRAIN
CONTROL
MODULE
43C1
1
SENSOR POSITION
THROTTLE
BK/LB20 K4
K4
20
BK/LB
CAMSHAFT
POSITION
SENSOR
2A
BK/LB18 K4
K4
20
BK/LB
2
SENSOR KNOC

Page 610 of 1200

DODGE NEON 1999 Service Repair Manual 8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch.................8W-80-4
A/C Cycling Switch....................8W-80-4
A/C Heater Blower Motor...............8W-80-4
A/C Heater Control....

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch.................8W-80-4
A/C Cycling Switch....................8W-80-4
A/C Heater Blower Motor...............8W-80-4
A/C Heater Control....................8W-80-4
A/C High Pressure Switch..............8W-80-4
A/C Low Pressure Switch...............8W-80-5
Airbag Control Module.................8W-80-5
Ash Receiver Lamp....................8W-80-6
Back-Up Lamp Switch.................8W-80-6
Battery Temperature Sensor.............8W-80-6
Blower Motor Resistor Block.............8W-80-6
Brake Warning Lamp Switch............8W-80-6
C101...............................8W-80-7
C102...............................8W-80-7
C103...............................8W-80-7
C104...............................8W-80-8
C105...............................8W-80-8
C108...............................8W-80-8
C160...............................8W-80-8
C161...............................8W-80-8
C170...............................8W-80-9
C205...............................8W-80-9
C206..............................8W-80-10
C225..............................8W-80-10
C230..............................8W-80-10
C231..............................8W-80-11
C241..............................8W-80-12
C242..............................8W-80-12
C301..............................8W-80-12
C303..............................8W-80-12
C309..............................8W-80-12
C340..............................8W-80-13
C341..............................8W-80-13
Camshaft Position Sensor..............8W-80-14
Center High Mounted Stop Lamp........8W-80-14
Cigar Lighter/Power Outlet.............8W-80-14
Clockspring.........................8W-80-14
Clutch Pedal Position Switch...........8W-80-15
Controller Anti-Lock Brake.............8W-80-15
Crankshaft Position Sensor.............8W-80-16
Data Link Connector..................8W-80-1
Daytime Running Lamp Module.........8W-80-16Component Page
Dome Lamp........................8W-80-17
Downstream Heated Oxygen Sensor......8W-80-17
Driver Door Lock Motor...............8W-80-17
Driver Door Lock Switch...............8W-80-17
Driver Power Window Motor............8W-80-17
Driver Power Window Switch...........8W-80-18
Driver Side Airbag...................8W-80-18
Duty Cycle Evap/Purge Solenoid.........8W-80-18
EGR Transducer Solenoid..............8W-80-19
Engine Coolant Temperature Sensor......8W-80-18
Engine Oil Pressure Switch............8W-80-19
Fog Lamp Switch....................8W-80-19
Front Fog Lamp Switch...............8W-80-19
Fuel Injector No. 1...................8W-80-19
Fuel Injector No. 2...................8W-80-19
Fuel Injector No. 3...................8W-80-20
Fuel Injector No. 4...................8W-80-20
Fuel Pump Module...................8W-80-20
Generator..........................8W-80-20
Glove Box Lamp And Switch............8W-80-20
Halo Lamp.........................8W-80-21
Headlamp Dimmer And Optical
Horn Switch......................8W-80-21
Headlamp Leveling Switch.............8W-80-21
Headlamp Switch....................8W-80-21
Heater Blower Motor.................8W-80-21
High Speed Warning Module...........8W-80-22
Horn..............................8W-80-22
Horn No. 1.........................8W-80-22
Horn No. 2.........................8W-80-22
IAT/Map Sensor.....................8W-80-25
Idle Air Control Motor.................8W-80-22
Ignition Coil Pack....................8W-80-22
Ignition Switch......................8W-80-23
Immobilizer.........................8W-80-23
Immobilizer Engine Sensor.............8W-80-23
Instrument Cluster-C1................8W-80-24
Instrument Cluster-C2................8W-80-24
Intermittent Wipe/Wash Switch.........8W-80-25
Key-In Switch.......................8W-80-25
Knock Sensor.......................8W-80-25
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

Page 627 of 1200

DODGE NEON 1999 Service Repair Manual CAV CIRCUIT FUNCTION
1 K52 20PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
2 F12 20DG/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
CAV CIRCUIT FUNCTION
1 K4 20BK/LB * SENSOR GROUND
1 K4 20BK/RD **

Page 643 of 1200

DODGE NEON 1999 Service Repair Manual CAV CIRCUIT FUNCTION
1- -
2 K19 18BK/GY IGNITION COIL NO. 1, 3 DRIVER
3 K17 18DB/TN IGNITION COIL NO. 2, 4 DRIVER
4 K20 18DG GENERATOR FIELD DRIVER
5 V32 20YL/RD SPEED CONTROL FEED
6 A142 18DG

Page 721 of 1200

DODGE NEON 1999 Service Repair Manual cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test r

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
9 - 8 ENGINEPL
DIAGNOSIS AND TESTING (Continued)

Page 824 of 1200

DODGE NEON 1999 Service Repair Manual INTAKE MANIFOLDÐDOHC ENGINE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WH

Page 826 of 1200

DODGE NEON 1999 Service Repair Manual INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.

INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.
29) to 28 N´m (250 in. lbs.).
(2) Install intake manifold onto cylinder head and
tighten fasteners to 28 N´m (250 in. lbs.) in sequence
shown in (Fig. 30).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect heater tube and hose to intake mani-
fold.
(7) Connect upper radiator hose and coolant recov-
ery hose.
(8) Connect coolant temperature sensor wiring con-
nector.
(9) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.).
(10) Connect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP) wiring connector.(11) Connect knock sensor connector and starter
wires. Connect wiring harness to heater tube tab.
(12) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(13) Connect vacuum hoses to throttle body.
(14) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(15) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(16) Install fresh air duct to air filter housing.
Tighten clamp to 3 N´m (25 in. lbs.).
(17) Connect negative cable to battery.
(18) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Remove air cleaner assembly and bracket.
(2) Remove exhaust manifold heat shield (Fig. 31).
(3) Disconnect upstream heated oxygen sensor con-
nector.
Fig. 29 Lower Intake Manifold to Upper Tightening
Sequence
Fig. 30 Intake Manifold To Cylinder Head Tightening
Sequence
Fig. 31 Exhaust Manifold Heat Shield
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

Page 861 of 1200

DODGE NEON 1999 Service Repair Manual FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 21
MODES OF OPERATION.................. 21
DESCRIPTION AND OPERATION
AIR CONDITIONING CLUTCH RELAYÐ
PCM

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

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