2000 DODGE NEON Service Repair Manual

REAR FRAME SECTION SIDE AND BOTTOM VIEW
13 - 12 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

STRUCTURAL DIMENSIONS
Structural dimensions are listed in metric mea-
surements. All dimensions are from center to center
of Principal Locating Point (PLP), or from center to
center of PLP and fastener location.
ENGINE COMPARTMENT TOP VIEW
ENGINE COMPARTMENT SIDE VIEW
PLFRAME AND BUMPERS 13 - 13
SPECIFICATIONS (Continued)

ENGINE COMPARTMENT BOTTOM VIEW
REAR FRAME SECTION SIDE VIEW
13 - 14 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Bumper Reinforcement
Nut................... 156N´m(115ft.lbs)
Rear Bumper Reinforcement
Nut................... 156N´m(115ft.lbs)
Front Crossmember To Body Mounting
Bolts.................. 163N´m(120 ft. lbs)
REAR FRAME SECTION BOTTOM VIEW
PLFRAME AND BUMPERS 13 - 15
SPECIFICATIONS (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY SYSTEM.................... 1FUEL INJECTION SYSTEM.................. 21
FUEL DELIVERY SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FUEL REQUIREMENTS.....................1
GASOLINE/OXYGENATE BLENDS.............2
FUEL DELIVERY SYSTEM...................3
FUEL PUMP MODULE......................3
ELECTRIC FUEL PUMP.....................4
FUEL GAUGE SENDING UNIT................4
FUEL FILTER/FUEL PRESSURE REGULATOR....4
FUEL TANK..............................4
FUEL RAIL...............................4
FUEL INJECTORS.........................5
PRESSURE-VACUUM FILLER CAP............5
ONBOARD REFUELING VAPOR RECOVERY....6
CONTROL VALVE/PRESSURE RELIEF.........6
QUICK-CONNECT FITTINGS.................6
ROLLOVER VALVES.......................7
FUEL TUBES/LINES/HOSES AND CLAMPS......8
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE...........................8INJECTOR CONNECTOR....................8
DRAINING FUEL TANK.....................9
HOSES AND CLAMPS......................9
QUICK-CONNECT FITTINGS.................9
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN RELAY............12
FUEL PUMP RELAY.......................12
FUEL PUMP MODULE.....................12
FUEL FILTER / PRESSURE REGULATOR......13
FUEL PUMP INLET STRAINER..............14
FUEL LEVEL SENSOR.....................14
FUEL INJECTORS........................15
FUEL TANK.............................16
FUEL FILLER NECK.......................17
ACCELERATOR PEDAL....................18
THROTTLE CABLE.......................19
SPECIFICATIONS
TORQUE...............................20
DESCRIPTION AND OPERATION
FUEL REQUIREMENTS
OPERATION
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavyspark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
The American Automobile Manufacturers Associa-
tion, AAMA, has issued gasoline specifications to
define the minimum fuel properties necessary to
deliver enhanced performance and durability for your
vehicle. DaimlerChrysler Corporation recommends
the use of gasoline that meet the AAMA specifica-
tions if they are available.
PLFUEL SYSTEM 14 - 1

REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformulat-
edº gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
DaimlerChrysler Corporation strongly supports the
use of reformulated gasoline. Properly blended refor-
mulated gasoline will provide excellent performance
and durability for the engine and fuel system compo-
nents.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. DaimlerChrysler rec-
ommends that gasoline without MMT be used in your
vehicle. The MMT content of gasoline may not be
indicated on the gasoline pump; therefore, you should
ask your gasoline retailer whether or not his/her gas-
oline contains MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with clean-burning, low-sul-
fur, California gasoline. Gasoline sold outside of Cal-
ifornia is permitted to have higher sulfur levels
which may affect the performance of the vehicle's cat-
alytic converter. This may cause the Check Engine or
Service Engine Soon light to illuminate.
Illumination of either light while operating on high
sulfur gasoline does not necessarily mean your emis-
sion control system is malfunctioning. DaimlerChrysler
recommends that you try a different brand of unleadedgasoline having lower sulfur to determine if the prob-
lem is fuel related prior to returning your vehicle to an
authorized dealer for service.
CAUTION: If the Check Engine or Service Engine
Soon light is flashing, immediate service is
required; see on-board diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
GASOLINE/OXYGENATE BLENDS
OPERATION
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
(Methyl Tertiary Butyl Ether) and ETBE (Ethyl Ter-
tiary Butyl Ether). Oxygenates are required in some
areas of the country during winter months to reduce
14 - 2 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

carbon monoxide emissions. The type and amount of
oxygenate used in the blend is important.
The following are generally used in gasoline
blends:
Ethanol- (Ethyl or Grain Alcohol) properly
blended, is used as a mixture of 10 percent ethanol
and 90 percent gasoline. Gasoline blended with etha-
nol may be used in your vehicle.
MTBE/ETBE- Gasoline and MTBE (Methyl Ter-
tiary Butyl Ether) blends are a mixture of unleaded
gasoline and up to 15 percent MTBE. Gasoline and
ETBE (Ethyl Tertiary Butyl Ether) are blends of gas-
oline and up to 17 percent ETBE. Gasoline blended
with MTBE or ETBE may be used in your vehicle.
Methanol- Methanol (Methyl or Wood Alcohol) is
used in a variety of concentrations blended with
unleaded gasoline. You may encounter fuels contain-
ing 3 percent or more methanol along with other
alcohols called cosolvents.
DO NOT USE GASOLINE CONTAINING
METHANOL.
Use of methanol/gasoline blends may result in
starting and driveability problems and damage criti-
cal fuel system components.
Problems that are the result of using methanol/
gasoline blends are not the responsibility of
DaimlerChrysler Corporation and may not be covered
by the vehicle warranty.
Reformulated Gasoline
Many areas of the country are requiring the use of
cleaner-burning fuel referred to asReformulated
Gasoline. Reformulated gasoline are specially
blended to reduce vehicle emissions and improve air
quality.
DaimlerChrysler Corporation strongly supports the
use of reformulated gasoline whenever available.
Although your vehicle was designed to provide opti-
mum performance and lowest emissions operating on
high quality unleaded gasoline, it will perform
equally well and produce even lower emissions when
operating on reformulated gasoline.
Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents of similar ingredients that can be harmful to
fuel system gasket and diaphragm materials.
FUEL DELIVERY SYSTEM
OPERATION
The fuel delivery system consists of: the electric
fuel pump, fuel filter/fuel pressure regulator, fuel
tubes/lines/hoses, fuel rail, fuel injectors, fuel tank,
accelerator pedal and throttle cable.A fuel return system is used on all models (all
engines). Fuel is returned through the fuel pump
module and back into the fuel tank through the fuel
filter/fuel pressure regulator. A separate fuel return
line from the engine to the tank is no longer used
with any engine.
The fuel tank assembly consists of: the fuel tank,
filler tube, fuel gauge sending unit/electric fuel pump
module, a rollover valve(s) and a pressure-vacuum
filler cap.
Also to be considered part of the fuel system is the
evaporation control system or Onboard Refueling
Vapor recovery (ORVR). This is designed to reduce
the emission of fuel vapors into the atmosphere. The
description and function of the Evaporative Control
System is found in the Emission Control Systems
section.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module is installed in the fuel tank
(Fig. 1).
OPERATION
The fuel pump module contains the following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer
²Fuel filter/pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
Fig. 1 Fuel Pump Module
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± FUEL LEVEL SENSOR
3 ± FUEL RESERVOIR
4 ± INLET STRAINER
5 ± FLOAT
PLFUEL SYSTEM 14 - 3
DESCRIPTION AND OPERATION (Continued)