2000 DODGE NEON engine

SPECIFICATIONS
STARTER MOTOR
Engine Application 2.0L OHC - DOHC
Power rating 1.1 Kw
Voltage 12 VOLTS
No. of Fields 6
No. of Poles 6
Brushes 4
Drive Planetary Gear Train
Cranking Amperage Draw
test150 - 280 Amps.
Note:Engine should be up to operating tempera-
ture. Extremely heavy oil or tight engine will
increase starter amperage draw.
TORQUE
DESCRIPTION TORQUE
Starter Mounting Bolts....... 54N´m(40ft.lbs.)
Starter Solenoid Battery Nut . . 10 N´m (90 in. lbs.)
PLSTARTING SYSTEMS 8B - 9

CHARGING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
CHARGING SYSTEM.......................1
GENERATOR.............................1
ELECTRONIC VOLTAGE REGULATOR..........1
REMOVAL AND INSTALLATION
GENERATOR.............................2SPECIFICATIONS
GENERATOR RATINGS.....................3
TORQUE................................3
DESCRIPTION AND OPERATION
CHARGING SYSTEM
DESCRIPTION
The charging system consists of:
²Generator
²Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
²Ignition switch (refer to the Ignition System for
information)
²Battery (refer to the Battery for information)
²Battery temperature sensor
²Wiring harness and connections (refer to the
Wiring for information)
OPERATION
The charging system is turned on and off with the
ignition switch. When the ignition switch is turned to
the ON position, battery voltage is applied to the
generator rotor through one of the two field termi-
nals to produce a magnetic field. The generator is
driven by the engine through a serpentine belt and
pulley arrangement.
The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry,
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground.
Temperature data, along with data from monitored
line voltage, is used by the PCM to vary the battery
charging rate. This is done by cycling the ground
path to control the strength of the rotor magnetic
field. The PCM then compensates and regulates gen-
erator current output accordingly and to maintain
the proper voltage depending on battery tempera-
ture.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including the
EVR (field control) circuitry, are monitored by thePCM. Each monitored circuit is assigned a Diagnos-
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine. It is
serviced only as a complete assembly. If the genera-
tor fails for any reason, the entire assembly must be
replaced.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicles electrical system
through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused
by:
²Worn, loose or defective bearings
²Loose or defective drive pulley
²Incorrect, worn, damaged or misadjusted drive
belt
²Loose mounting bolts
²Misaligned drive pulley
²Defective stator or diode
²Damaged internal fins
ELECTRONIC VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
PLCHARGING SYSTEM 8C - 1

(2) Install lower pivot bracket and tighten bolts to
54 N´m (40 ft. lbs.).(3) Loose install the upper and lower mounting
bolts (Fig. 3).
(4) Connect the generator field circuit wiring con-
nector. Push theREDlocking tab to lock.
(5) Install the B+ terminal nut and wire.
(6) Install the generator drive belt.
(7) Lower vehicle.
(8) Tension belt.
(9) Tighten adjustment bolt.
(10) Tighten the jam nut
(11) Raise vehicle and support.
(12) Tighten lower mounting bolt and tighten bolts
to 54 N´m (40 ft. lbs.)..
(13) Install splash shield (Fig. 2).
(14) Lower vehicle.
(15) Connect battery cable (Fig. 1).
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
Mitsubishi 4794222AA 85 AMPS 2.0L 75 AMPS
TORQUE
DESCRIPTION TORQUE
Battery Terminal Nut......... 9N´m(75in.lbs.)
Battery Hold Down Clamp Bolt . . 9 N´m (75 in. lbs.)
Generator Mounting Bolt..... 54N´m(40ft.lbs.)
Generator Pivot Bolt......... 54N´m(40ft.lbs.)
Pivot Bracket Bolts.......... 54N´m(40ft.lbs.)
Fig. 4 Generator
PLCHARGING SYSTEM 8C - 3
REMOVAL AND INSTALLATION (Continued)

IGNITION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
IGNITION SYSTEM........................1
SPARK PLUGS...........................1
SPARK PLUG CABLES.....................1
ELECTRONIC IGNITION COILS...............2
AUTOMATIC SHUTDOWN RELAY.............2
CRANKSHAFT POSITION SENSORÐPCM
INPUT................................3
CAMSHAFT POSITION SENSORÐPCM
INPUT................................4
KNOCK SENSOR..........................5
IGNITION SWITCH........................5
LOCK KEY CYLINDER......................5
IGNITION INTERLOCK.....................6
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE....................6SPARK PLUG CABLE SERVICE..............6
IGNITION COIL...........................6
AUTOMATIC SHUTDOWN RELAY.............6
CAMSHAFT POSITION SENSOR..............6
CRANKSHAFT POSITION SENSOR............8
KNOCK SENSOR..........................8
IGNITION SWITCH........................8
LOCK KEY CYLINDER......................9
IGNITION INTERLOCK....................10
SPECIFICATIONS
VECI LABEL............................10
FIRING ORDERÐ2.0L....................10
TORQUE SPECIFICATION..................11
SPARK PLUG CABLE RESISTANCEÐSOHC....11
SPARK PLUG...........................11
IGNITION COIL..........................11
DESCRIPTION AND OPERATION
IGNITION SYSTEM
DESCRIPTION
The system's three main components are the coil
pack, crankshaft position sensor, and camshaft posi-
tion sensor.
OPERATION
Basic ignition timing is not adjustable.The
Powertrain Control Module (PCM) determines spark
advance. The 2.0L engines use a fixed ignition timing
system. The distributorless electronic ignition system
is referred to as the Direct Ignition System (DIS).
SPARK PLUGS
The 2.0L engines uses resistor spark plugs. For
spark plug identification and specifications, Refer to
the Specifications section at the end of this group.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. Aftercleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the
electrodes (Fig. 1) to the dimensions specified in the
chart at the end of this section by bending the
ground electrode (just above the attachment weld)
with the appropriate tool.
Never apply any force between the electrode or
damage to the center electrode assembly will result.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion and damage.
Tighten spark plugs to 28 N´m (20 ft. lbs.) torque.
SPARK PLUG CABLES
Spark plug cables are sometimes referred to as sec-
ondary ignition wires. The wires transfer electrical
current from the coil pack to individual spark plugs
at each cylinder. The resistor type, nonmetallic spark
plug cables provide suppression of radio frequency
emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil and spark plugs. Terminals should
be fully seated. The nipples and spark plug covers
should be in good condition. Nipples should fit tightly
on the coil. Spark plug boot should completely cover
the spark plug hole in the cylinder head cover. Install
the boot until the terminal snaps over the spark
plug. A snap must be felt to ensure the spark plug
cable terminal engaged the spark plug.
PLIGNITION SYSTEM 8D - 1

OPERATION
The Automatic Shutdown (ASD) relay supplies bat-
tery voltage to the fuel injectors, electronic ignition
coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC)
supplies voltage to the solenoid side and contact side
of the relay. The fuse also protects the power circuit
for the fuel pump relay and pump. The fuse is
located in the PDC. Refer to the Wiring Diagrams for
circuit information.
The PCM controls the ASD relay by switching the
ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the
ignition switch is in the Off position. When the igni-
tion switch is in On or Start, the PCM monitors the
crankshaft and camshaft position sensor signals to
determine engine speed and ignition timing (coil
dwell). If the PCM does not receive crankshaft and
camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the
ASD relay.
CRANKSHAFT POSITION SENSORÐPCM
INPUT
DESCRIPTION
The crankshaft position sensor mounts to the
engine block behind the generator, just above the oil
filter (Fig. 4).
The PCM uses the Crankshaft Position sensor to
calculate the following:
²Engine RPM²TDC number 1 and 4
²Ignition coil synchronization
²Injector synchronization
²Camshaft-to-crankshaft misalignment (Timing
belt skipped 1 tooth or more diagnostic trouble code).
OPERATION
The Crankshaft Position (CKP) sensor is a Hall-ef-
fect sensor. The second crankshaft counterweight has
two sets of four timing reference notches including a
60 degree signature notch (Fig. 5).
Fig. 5 Timing Reference Notches
1 ± MACHINED NOTCHES
2 ± CRANKSHAFT POSITION SENSOR
Fig. 4 Crankshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± OIL FILTER
3 ± GENERATOR
PLIGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)

The PCM sends approximately 8 volts to the Hall-
effect sensor. This voltage is required to operate the
Hall-effect chip and the electronics inside the sensor.
A ground for the sensor is provided through the sen-
sor return circuit. The input to the PCM occurs on a
5 volt output reference circuit.
The notches generate pulses from high to low in
the crankshaft position sensor output voltage. When
a metal portion of the counterweight aligns with the
crankshaft position sensor, the sensor output voltage
goes low (less than 0.5 volts). When a notch aligns
with the sensor, voltage goes high (5.0 volts). As a
group of notches pass under the sensor, the output
voltage switches from low (metal) to high (notch)
then back to low.
If available, an oscilloscope can display the square
wave patterns of each voltage pulses. From the width
of the output voltage pulses, the PCM calculates
engine speed. The width of the pulses represent the
amount of time the output voltage stays high before
switching back to low. The period of time the sensor
output voltage stays high before switching back to
low is referred to as pulse width. The faster the
engine is operating, the smaller the pulse width on
the oscilloscope.
By counting the pulses and referencing the pulse
from the 60 degree signature notch, the PCM calcu-
lates crankshaft angle (position). In each group of
timing reference notches, the first notch represents
69 degrees before top dead center (BTDC). The sec-
ond notch represents 49 degrees BTDC. The third
notch represents 29 degrees. The last notch in each
set represents 9 degrees before top dead center
(TDC).
The timing reference notches are machined at 20É
increments. From the voltage pulse width the PCM
tells the difference between the timing reference
notches and the 60 degree signature notch. The 60
degree signature notch produces a longer pulse width
than the smaller timing reference notches. If the
camshaft position sensor input switches from high to
low when the 60 degree signature notch passes under
the crankshaft position sensor, the PCM knows cylin-
der number one is the next cylinder at TDC.CAMSHAFT POSITION SENSORÐPCM INPUT
DESCRIPTION
The camshaft position sensor attaches to the rear
of the cylinder head. The PCM determines fuel injec-
tion synchronization and cylinder identification from
inputs provided by the camshaft position sensor (Fig.
6) and crankshaft position sensor. From the two
inputs, the PCM determines crankshaft position.
OPERATION
The PCM sends approximately 8 volts to the hall
affect sensor. This voltage is required to operate the
hall effect chip and the electronics inside the sensor.
A ground for the sensor is provided through the sen-
sor return circuit. The input to the PCM occurs on a
5 volt output reference circuit.
A target magnet attaches to the rear of the cam-
shaft and indexes to the correct position. The target
magnet has four different poles arranged in an asym-
metrical pattern (Fig. 7). As the target magnet
rotates, the camshaft position sensor senses the
change in polarity (Fig. 8). The sensor output switch
switches from high (5.0 volts) to low (0.5 volts) as the
target magnet rotates. When the north pole of the
target magnet passes under the sensor, the output
switches high. The sensor output switches low when
the south pole of the target magnet passes under-
neath.
The sensor also acts as a thrust plate to control
camshaft endplay.
Fig. 6 Camshaft Position SensorÐSOHC
8D - 4 IGNITION SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
IGNITION SWITCH
In the RUN position, the ignition switch connects
power from the Power Distribution Center (PDC) to a
fuse in the fuse block, back to a bus bar in the PDC.
The bus bar feeds circuits for the Powertrain Control
Module (PCM), Proportional purge solenoid, EGR
solenoid, and ABS system. The bus bar in the PDC
feeds the coil side of the radiator fan relay, A/C com-
pressor clutch relay, and the fuel pump relay. It also
feeds the Airbag Control Module (ACM)
LOCK KEY CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 9) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
Fig. 7 Target MagnetÐTypical
1 ± CAM MAGNET/TARGET
2 ± CAMSHAFT POSITION SENSOR
Fig. 8 Target Magnet Polarity
1 ± TARGET MAGNET
Fig. 9 Ignition Lock Cylinder Detents
PLIGNITION SYSTEM 8D - 5
DESCRIPTION AND OPERATION (Continued)

IGNITION INTERLOCK
OPERATION
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Off, Run or Start position. In addi-
tion, the operator cannot rotate the key to the lock
position unless the shifter is in the park position. On
vehicles equipped with floor shift refer to the - Tran-
saxle for Automatic Transmission Shifter/Ignition
Interlock.
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
REMOVAL
REMOVE CABLES FROM COIL FIRST.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
(1) Remove the spark plug using a quality socket
with a rubber or foam insert.
(2) Inspect the spark plug condition.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube.
Reconnect to coil.
SPARK PLUG CABLE SERVICE
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
REMOVAL
Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube. The connect theother end to coil pack. Be sure that dual plastic clip
holds the cables off of the valve cover.
IGNITION COIL
The electronic ignition coil pack attaches directly
to the valve cover (Fig. 11).
REMOVAL
(1) Disconnect electrical connector from coil pack
(Fig. 10).
(2) Remove coil pack mounting bolts.
(3) Remove coil pack.
INSTALLATION
(1) Install coil pack on valve cover.
(2) Transfer spark plug cables to new coil pack.
The coil pack towers are numbered with the cylinder
identification. Be sure the ignition cables snap onto
the towers.
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 12). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
CAMSHAFT POSITION SENSOR
The camshaft position sensor is mounted to the
rear of the cylinder head (Fig. 13).
Fig. 10 Electronic Ignition Coil Connector
1 ± COIL
2 ± LOCKING TAB
8D - 6 IGNITION SYSTEMPL
DESCRIPTION AND OPERATION (Continued)