1999 DODGE NEON tow

8W-95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of the splices in this vehicle. A splice
index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for proper splice number.
SPLICE LOCATIONS (LHD)
The following index covers all splices shown in the
wiring diagrams. If a splice is not shown in this sec-
tion, a N/S will be in the Fig. column.
Spllice Location Fig.
S101 Near Dat Link T/O 1
S104 Left Strut Tower 1
S105 Left Strut Tower 1
S106 Near PCM T/O 1
S107 Before T/O for Left
Headlamp2
S108 Before T/O for Left
Headlamp2
S109 Before T/O for Left
Headlamp2
S110 In PCM T/O 1
S111 Near T/O for Radiator Fan
Motor2
S112 Near T/O for Left Headlamp 2
S113 Near T/O for Left Headlamp 2
S114 Near T/O for Left Headlamp 2
S115 Neat T/O for Radiator Fan
Motor2
S116 Near T/O for Radiator Fan
Motor2
S117 Near EVAP/Purge Sol T/O 2
S118 Between VSS and Crank
Sensor T/O3
S119 Between Crank Sensor and
VSS T/O3
S120 Near INJ #4 3
S121 Between INJ #2 and #3 T/O 3
S122 Near T/O for VSS and
Engine Oil Pressure Switch3
S123 Near T/O for O2S 3
S124
SOHCNear Cam Sensor and Coil
T/O'sN/S
S124
DOHCNear TP Sensor T/O 3Spllice Location Fig.
S125 Near Starter N/S
S126 In PCM T/O N/S
S127 Near Left Headlamp T/O 2
S131 Near T/O for PCM 1
S133 In Left Headlamp Leveling
T/ON/S
S139 In Ignition Coil 3
S201 Near T/O for Center Console 5
S202 Near T/O for PAB 4
S203 Near T/O for Passenger Air
Bag4
S204 Near HVAC Connector 4
S205 Near Center Stack T/O 4
S206 Near Center Stack T/O 4
S207 Top Center of I.P. 5
S208 Top Center of I.P. 5
S209 Top Center of I.P. 5
S210 Top Center of I.P. 5
S211 Between RT and LT Cluster
T/O's5
S212 Between RT and LT Cluster
T/O's5
S213 Near T/O for Left Cluster 4
S214 Near T/O for Fuseblock 4
S216 Near STRG Column T/O 4
S217 Near T/O for Fuse Block 4
S218 Between RT and LT Cluster
T/O's4
S219 In T/O for RKE Module 5
S221 In T/O for Body Wiring 4
S222 Near T/O for Fuse Block 4
S223 Top Center of I/P 4
PL8W - 95 SPLICE LOCATIONS 8W - 95 - 1

SPLICE LOCATIONS (RHD)
The following index covers all splices shown in the
wiring diagrams. If a splice is not shown in this sec-
tion, a N/S will be in the Fig. column.
Spllice Location Fig.
S101 Near Dat Link T/O 1
S104 Right Strut Tower 1
S105 Left Strut Tower N/S
S106 Near PCM T/O 1
S107 Before T/O for Left Headlamp
Leveling2
S108 Near T/O for Left Headlamp
Leveling2
S109 Before T/O for Left Headlamp
Leveling2
S110 In PCM T/O 1
S111 Near T/O for Radiator Fan
Motor2
S112 Near T/O for Left Headlamp 2
S113 Near T/O for Left Headlamp 2
S114 Near T/O for Left Headlamp 2
S115 Near T/O for Radiator Fan
Motor2
S116 Near T/O for Left Fog Lamp 2
S117 Near EVAP/Purge Sol T/O 2
S118 Between VSS and Crank
Sensor T/O3
S119 Between Crank Sensor and
VSS T/O3
S120 Near INJ #4 3
S121 Between INJ #2 and #3 T/O 3
S122 Near T/O for VSS and Engine
Oil Pressure Switch3
S123 Near T/O for O2S 3
S124 Near Cam Sensor and Coil
T/O's3
S125 Near Starter N/S
S126 In PCM T/O N/S
S127 Near Left Headlamp T/O 2
S131 Near T/O for PCM 1
S133 In Left Headlamp Leveling T/O N/S
S139 In Ignition Coil 3
S201 Near T/O for Center Console N/S
S202 Near T/O for PAB 5
Spllice Location Fig.
S203 Near T/O for HVAC 5
S204 Near HVAC Connector 5
S205 Near Center Stack T/O 5
S206 Near Center Stack T/O 5
S207 Top Center of I.P. 4
S208 Top Center of I.P. 4
S209 Top Center of I.P. 4
S210 Top Center of I.P. 4
S211 Between RT and LT Cluster
T/O's4
S212 Between RT and LT Cluster
T/O's4
S213 Near T/O for Left Fuseblock 4
S214 Right Cluster and Right Panel
speaker4
S217 Near T/O for FuseBlock 4
S218 Between RT and LT Cluster
T/O's4
S221 Top Right of I.P. 4
S222 Near T/O for FuseBlock 4
S223 Top Center of I/P 5
S224 In T/O for Headlamp Switch 4
S301 Near RT B-Pillar T/O 7
S302 Near RT B-Pillar T/O 7
S303 Near RT B-Pillar T/O 7
S304 Near Fuel Tank T/O 7
S306 Near Fuel Tank T/O 7
S307 Near Rear Fog Lamp T/O 7
S308 Near LR Body Ground 6
S309 Near Top of A-Pillar, Left Side 9
S310 Near DR/LK SW and PWR
Mirror T/O8
S313 Near T/O for Sunroof Slide
SW9
S314 Near T/O for Sunroof Slide
Switch9
S315 Near Rear Fog Lamp T/O 6
S316 Near Fuel Tank T/O 7
S317 Near Fuel Tank T/O 7
S318 Near DR/LK Switch T/O 8
PL8W - 95 SPLICE LOCATIONS 8W - 95 - 11
DESCRIPTION AND OPERATION (Continued)

assure gasket rails are flat. Flatten rails with a ham-
mer on a heavy steel plate if required. Gasket sur-
faces must be free of oil and dirt. Make sure old
gasket material is removed from blind attaching
holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 inch.) diameter or less of seal-
ant to one gasket surface. Be certain the material
surrounds each mounting hole. Excess material can
easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
The MopartSilicone Rubber Adhesive Sealant gas-
ket material or equivalent should be applied in a con-
tinuous bead approximately 3 mm (0.120 inch) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.)
drop is placed in the center of the gasket contact
area. Uncured sealant may be removed with a shop
towel. Components should be torqued in place while
the sealant is still wet to the touch (within 10 min-
utes). The usage of a locating dowel is recommended
during assembly to prevent smearing material off the
location.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmly
with pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is atleast 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINEPL
GENERAL INFORMATION (Continued)

(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.)
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
CHECKING ENGINE OIL LEVEL
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Add only when the level is at or below the
ADD mark (Fig. 5).
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 6).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 7).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
Fig. 5 Oil Level
Fig. 6 Temperature/Engine Oil Viscosity
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)

MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up into the cylin-
der head. The rocker shafts route oil to the rocker
arms/hydraulic lash adjuster assemblies.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
B LY:A partial open deck is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4 mm. The bedplate
incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFT:A nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 52 mm diameter
main and 48 mm diameter crank pin journals (all)
have undercut fillet radiuses that are deep rolled for
added strength. To optimize bearing loading 8 coun-
terweights are used. Hydrodynamic seals provide end
sealing, where the crankshaft exits the block.
Anaerobic gasket material is used for parting line
sealing. A sintered iron timing belt sprocket is
mounted on the crankshaft nose. This sprocket trans-
mits crankshaft movement, via timing belt to the
camshaft sprocket providing timed valve actuation.
PISTONS:The SOHC EngineDOES NOThave
provision for a free wheeling valve train. Non free
wheeling valve train means, in the event of a broken
timing belt Pistons will contact the Valves. All
engines use pressed-in piston pins to attach forged
powdered metal connecting rods. The connecting rods
are a cracked cap design and are not repairable. Hex
head cap screw are used to provide alignment and
durability in the assembly. Pistons And Connecting
rods are serviced as an assembly.
PISTON RINGS:The piston rings include a
molybdenum faced top ring for reliable compression
sealing and a taper faced intermediate ring for addi-
tional cylinder pressure control. Oil Control Ring
Package consist of 2 steel rails and a expander
spacer.
CYLINDER HEADÐSOHC:It features a Single
Over Head Camshaft, four-valves per cylinder cross
flow design. The valves are arranged in two inlinebanks, with the two intake per cylinder facing
toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFTÐSOHC:The nodular iron camshaft
has five bearing journals and 3 cam lobes per cylin-
der. Provision for cam position sensor on the cam at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVESÐSOHC:Four valves per cylinder are
actuated by roller rocker arms/hydraulic lash adjust-
ers assemblies which pivot on rocker arm shafts. All
valves have 6 mm diameter chrome plated valve
stems. The valve train has 33 mm (1.299 inch) diam-
eter intake valves and 28 mm (1.10 inch) diameter
exhaust valves. Viton rubber valve stem seals are
integral with spring seats. Valve springs, spring
retainers, and locks are conventional design.
INTAKE MANIFOLD:The intake manifold is a
molded plastic composition, attached to the cylinder
head with ten fasteners. This long branch design
enhances low and mid-range torque.
EXHAUST MANIFOLD:The exhaust manifold is
made of nodular cast iron for strength and high tem-
peratures. Exhaust gasses exit through a machined,
articulated joint connection to the exhaust pipe.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 3). The cylin-
der bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
9 - 14 2.0L SOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

NOTE: Inspect the rocker arm for scoring, wear on
the roller or damage to the rocker arm (Fig. 24)
Replace if necessary. Check the location where the
rocker arms mount to the shafts for wear or dam-
age. Replace if damaged or worn. The rocker arm
shaft is hollow and is used as a lubrication oil duct.
Check oil holes for clogging with small wire, clean
as required. Lubricate the rocker arms and spacers.
Install onto shafts in their original position (Fig. 23).
INSTALLATION
CAUTION: Set crankshaft to 3 notches before TDC
before installing rocker arm shafts. Refer to Timing
Belt System and Camshaft Seal Service of this sec-
tion for procedure.
(1) Install rocker arm/hydraulic lash adjuster
assembly making sure that adjusters are at least
partially full of oil. This is indicated by little or no
plunger travel when the lash adjuster is depressed. If
there is excessive plunger travel. Place the rocker
arm assembly into clean engine oil and pump the
plunger until the lash adjuster travel is taken up. If
travel is not reduced, replace the assembly. Hydraulic
lash adjuster and rocker arm are serviced as an
assembly.
(2) Install rocker arm and shaft assemblies with
NOTCH in the rocker arm shafts pointing up and
toward the timing belt side of the engine (Fig. 25).
Install the retainers in their original positions on the
exhaust and intake shafts (Fig. 23).
CAUTION: When installing the intake rocker arm
shaft assembly be sure that the plastic spacers do
not interfere with the spark plug tubes. If the spac-
ers do interfere rotate until they are at the proper
angle. To avoid damaging the spark plug tubes, do
not attempt rotating the spacers by forcing down
the shaft assembly.(3) Tighten bolts to 28 N´m (250 in. lbs.) in
sequence shown in (Fig. 26).
HYDRAULIC LASH ADJUSTER NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster Noise - Diagnosis in
Standard Service Procedures, outlined in this Group.
Lash adjusters are replaced with the rocker
arm as an assembly.
VALVE SEALS AND SPRINGS IN VEHICLE
REMOVAL
(1) Remove rocker arm shafts assemblies as previ-
ously outlined in this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772A with adapter
6779 (Fig. 27) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 28).
Fig. 24 Rocker Arm Assemblies
Fig. 25 Rocker Arm Shaft Notches
Fig. 26 Rocker Arm Shaft Tightening Sequence
9 - 24 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(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. 66) 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.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Using Special Tool 1026 and Insert 6827±A,
remove crankshaft damper (Fig. 68).
(2) Remove outer timing belt cover and timing
belt. Refer to procedure outlined in this section.(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 69).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 70). Do not damage the seal contact area
on the crankshaft.
INSTALLATION
(1) Install new seal by using Tool 6780±1 (Fig. 71).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket (Fig. 72). Using
Special Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing you.
(4) Install timing belt and covers. Refer to Timing
Belt System in this section for installation.
Fig. 67 Oil Pan Sealing
Fig. 68 Crankshaft DamperÐRemoval
Fig. 69 Crankshaft SprocketÐRemoval
Fig. 70 Front Crankshaft Oil SealÐRemoval
PL2.0L SOHC ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 75).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 76) until the tool bot-
toms out against the block (Fig. 77).
CRANKSHAFT
REMOVAL
(1) Remove oil filter and adapter from bedplate.
(2) Remove structural collar from oil pan to tran-
saxle housing.
(3) Remove oil pan.
(4) Remove crankshaft sprocket and oil pump both
procedures outlined in this section.
(5) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 78).
(6) Using a mallet tap the bedplate loose from the
engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.
(7) Bedplate should be removed evenly from the
cylinder block dowel pins.(8) Lift out crankshaft from cylinder block. Be sure
not to damage the main bearings or journals when
removing the crankshaft.
Fig. 75 Rear Crankshaft Seal and Special Tool
6926-1
Fig. 76 Crankshaft Seal Special Tool 6926-2
Fig. 77 Rear Crankshaft SealÐInstallation
PL2.0L SOHC ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)