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Page 397 of 1200

DODGE NEON 1999 Service Repair Manual CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies the main circuit, part of the main
circuit, gage of wire, and color (Fig. 1)
CIRCUIT FUNCTIONS
All circuits in the

Page 616 of 1200

DODGE NEON 1999 Service Repair Manual CAV CIRCUIT
1 A1 14RD
2 A2 12PK/BK
3 A3 12RD/WT
4 A4 14BK/RDCAV CIRCUIT
1 A1 14RD
2 A2 12PK/BK
3 A3 12RD/WT
4 A4 14BK/RD BLACK
BLUE
BLACK
BLUE
12
3421
43
716
1816 7
81 CAV CIRCUIT
1 A41 14YL
2 C21 20D

Page 618 of 1200

DODGE NEON 1999 Service Repair Manual CAV CIRCUIT
1 F35 16RD/YL
2 P36 16PK/LB*
2 P36 16PK/VT
3 P35 16OR/WT*
3 P35 16OR/VT
4-
5 P33 16OR/BK
6 P34 16PK/BK
7 F21 14TN
8-
9 P90 22LG/BK
10 P91 22WT/BK
11 P92 22YL
12 P94 22WT/YL
13 Q16 14BR/WT

Page 619 of 1200

DODGE NEON 1999 Service Repair Manual CAV CIRCUIT
1 M1 18PK
2 M23 18YL/BK
3 Z3 18BK/OR
4-
5
6CAV CIRCUIT
1 M1 22PK
2 M23 20YL/BK*
3 Z3 20BK/OR
4-
5 F10 18YL/RD
6 Z8 18BK/VT REDRED
46
31
64
13
CAV CIRCUIT
1-
2G10 20LG/RD
3 G16 20BK/LB
4 P3

Page 620 of 1200

DODGE NEON 1999 Service Repair Manual *RKECAV CIRCUIT
1 F35 18RD/YL
2 P36 18PK/VT
3 P35 18OR/VT
4 Z8 14BK/VT
5 P33 18OR/BK
6 P34 18PK/BK
7 F21 14TN
8 M1 22PK
9P90 20LG/BK
P90 20LG/BK
10P91 20WT/BK
P91 20WT/BK
11 P92 22YL
12 P94 22WT/YL
13

Page 651 of 1200

DODGE NEON 1999 Service Repair Manual 61
CAV CIRCUIT FUNCTION
1 K29 20WT/PK STOP LAMP SWITCH SENSE
2 Z12 20BK/TN GROUND
3 V32 20YL/RD SPEED CONTROL FEED
4 V40 20WT/BR SWITCHED SPEED CONTROL POWER SUPPLY
5 L50 20WT/TN STOP LAMP

Page 761 of 1200

DODGE NEON 1999 Service Repair Manual 33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and l

33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and lift compress-
ing lever to set tone device (Fig. 105). Pull on torque
wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The Following specifications
apply to both intake and exhaust valve springs.
²Valve Closed Nominal ForceÐ 67 lbs. @ 39.8 mm
(1.57 in.)
²Valve Open Nominal ForceÐ 160 lbs. @ 32.6 mm
(1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.(2) Inspect the remaining margin after the valves
are refaced (Fig. 106). Intake valves with less than
0.95 mm (1/32 inch.) margin and Exhaust valves
with less than 1.05 mm (3/64 inch) margin should be
discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For valve specifications see Valve Specifica-
tion Chart.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
²Intake valve seat diameter is 33 mm (1.299 in.)
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake Valve Exhaust Valve
5.975 - 6.000
mm (0.2352 -
0.2362 in.)5.975 - 6.000
mm (0.2352 -
0.2362 in.)
Valve Guide Clearance
Intake Valve Exhaust Valve
New: 0.023 - 0.066
mm (0.001 -
0.0025 in.)0.051 - 0.094
mm (0.002 -
0.0037 in.)
Service Limit: 0.25 mm (0.010 in.)
Fig. 104 Valve Guide Height
Fig. 105 Valve Spring Testing
Fig. 106 Intake and Exhaust Valve Refacing
9 - 48 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

Page 805 of 1200

DODGE NEON 1999 Service Repair Manual Chart for specifications. Replace guides if they are
not within specification.
CHECK VALVE GUIDE HEIGHT
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or

Chart for specifications. Replace guides if they are
not within specification.
CHECK VALVE GUIDE HEIGHT
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested Special Tool C-647. As an example,
the compression length of the spring to be tested is
33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and lift compress-
ing lever to set tone device (Fig. 97). Pull on torque
wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The Following specifications
apply to both intake and exhaust valve springs:
²Valve Closed Compression Pressure: 246 ± 270 N
@ 38.0 mm (55 ± 60 lbs. @ 1.50 in.)
²Valve Open Compression Pressure: 549 ± 611 N
@ 29.25 mm (123 ± 137 lbs. @ 1.17 in.)
(2) Verify springs are not distorted with a steel
square and surface plate. Check springs from both
ends. Replace spring if the spring is more than 1.5
mm (1/16 inch) out of square.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 and a 45 1/2 degree angles.
(2) Inspect the remaining margin after the valves
are refaced (Fig. 98). Intake valves with less than 1.2
mm (3/64 inch.) margin and Exhaust valves with less
than 0.9 mm (1/32 inch.) margin should be discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for the
reseating stones. A true and complete surface must
be obtained.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
Fig. 96 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide
DiameterIntake Valve Exhaust Valve
5.975 - 6.000 mm
(0.2352 - 0.2362
in.)5.975 - 6.000 mm
(0.2352 - 0.2362
in.)
Valve Guide
ClearanceIntake Valve Exhaust Valve
New: 0.023 - 0.066 mm
(0.001 - 0.0025
in.)0.051 - 0.094 mm
(0.002 - 0.0037
in.)
Service Limit: 0.25 mm (0.010 in.)
Valve Guide Height
Fig. 97 Testing Valve Spring
9 - 92 2.0L DOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

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