2000 DODGE NEON length

(14) Adjust the parking brake shoes as necessary.
Refer to ADJUSTMENTS in this section of this ser-
vice manual group.
(15) Lower the vehicle.
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER (FRONT AND REAR)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING AND INSPECTION
in this section of this service manual group.
CALIPER GUIDE PIN BUSHING
REMOVAL
(1) With one hand, push the guide pin bushing
sleeve towards the back of the caliper, and at the
same time, pull the sleeve out the back of the caliper
and bushing (Fig. 111).
(2) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss
(Fig. 112).INSTALLATION
(1) Fold the guide pin bushing in half lengthwise
at the solid middle section (Fig. 113).
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
Fig. 111 Removing Sleeve From Bushing
1 ± CALIPER
2 ± SLEEVE
3 ± BUSHING
Fig. 112 Removing Bushing From Caliper
1 ± CALIPER
2 ± BUSHING
Fig. 113 Folded Caliper Guide Pin Bushing
1 ± CALIPER GUIDE PIN BUSHING
PLBRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)

Coolant flow circuit for the 2.0L engine is shown in
(Fig. 1).
During any reassembly procedures all pipe fittings
in water jacket, and water box require cleaning and
application of thread sealant for entire length of
threads.
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine block
metal and in the cylinder head area near the exhaust
valves. Then coolant carries this heat to the radiator
where the tube/fin assemblies can give off the heat to
the air.
MopartAntifreeze or the equivalent is recom-
mended for optimum cooling performance and corro-
sion protection when mixed to a freeze point of -37É C
(-35É F).
COOLANT REPLACEMENT
Refer to Group 0, Lubrication and Maintenance for
schedule.
COOLANT PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formula = 1 btu per minute for eachdegree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
²Pure Water (1 btu) boils at 100ÉC (212ÉF) and
freezes at 0ÉC (32ÉF).
²100 Percent Glycol (.7 btu) can cause a hot
engine and detonation and will raise the freeze point
to 22ÉC (-8ÉF).
²50/50 Glycol and Water (0.82 btu) is the recom-
mended combination that provides a freeze point of
-37ÉC (-35ÉF). The radiator, water pump, engine
water jacket, radiator pressure cap, thermostat, tem-
perature gauge, sending unit and heater are all
designed for 50/50 glycol.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of -59ÉC
(-50ÉF).
CAUTION: Richer mixtures cannot be measured
with field equipment which can lead to problems
associated with 100 percent glycol.SELECTION AND ADDITIVES
The use of aluminum cylinder heads, intake mani-
folds, and water pumps requires special corrosion
Fig. 1 Cooling System Operation
1 ± HEATER
2 ± HEAT UP
3 ± COOL DOWN
4 ± PRESSURE CAP
5 ± THERMOSTAT HOUSING6 ± WATER PUMP
7 ± ENGINE
8 ± COOLANT RECOVERY SYSTEM TANK
9 ± RADIATOR
7 - 2 COOLING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

(2) Connect recovery hose to water outlet connec-
tor/thermostat housing (Fig. 29).
(3) Fill container to proper level. Refer to Cooling
System Refilling in this section.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Draining in this section for
procedure.
(2) Detach power cord plug from heater (Fig. 31).
(3) Loosen screw in center of heater. Remove
heater assembly (Fig. 31).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward (Fig. 31).
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Connect power cord to block heater (Fig. 31).
(5) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks.
ACCESSORY DRIVE BELTS
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
REMOVAL
(1) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be removed from
power steering pump pulley. Gently, release spring
tension on tensioner.
(2) Remove belt (Fig. 34).
INSTALLATION
(1) Install belt (Fig. 34) over all pulleys except for
the power steering pump pulley.
(2) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 33) until belt can be installed onto
power steering pulley. Release spring tension onto
belt.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 35). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
Fig. 31 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
Fig. 32 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
7 - 24 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(3) Install power steering pump and A/C compres-
sor drive belt.
AUTOMATIC BELT TENSIONER & PULLEY
The automatic belt tensioner (Fig. 37) maintains
proper tension on the power steering and air condi-
tioning belt. The tensioner is serviced with the
engine mount bracket assembly. The tensioner pulley
can be serviced.
NOTE: Slight axial movement of the tensioner arm
is normal. Tensioner arm should move freely and
maintain 50±70 lb. tension on belt.
REMOVAL
(1) Remove engine mount bracket assembly. Refer
to Group 9, Engine for procedure.
(2) Remove tensioner pulley mounting bolt.
(3) Remove pulley.
INSTALLATION
(1) Install tensioner pulley and bolt. Tighten bolt
to 27 N´m (20 ft. lbs.).
(2) Install engine mount bracket assembly. Refer
to Group 9, Engine for procedure.
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE
The cooling fan module consist of the following
three components: fan, fan motor, and shroud.
Fig. 35 Belt Length Indicator Marks
1 ± AUTOMATIC BELT TENSIONER
2 ± BELT LENGTH INDICATOR
3 ± MAXIMUM BELT LENGTH
4 ± NOMINAL BELT LENGTH
5 ± MINIMUM BELT LENGTH
Fig. 36 Generator Belt Adjustment
1 ± ADJUSTING BOLT
2 ± LOCKING NUT
3 ± PIVOT BOLT
BELT TENSION CHART
Accessory
Drive BeltBelt Tension Belt Deflection
at Center Span*
Power Steering
Pump and A/C
CompressorDynamic Tensioner
GeneratorNew 135 lb. 4.5 mm (0.18 in.)
Used 100 lb. 5.5 mm (0.22 in.)
* Belt deflection is measured at the center of the belt
span with 4.5 kg (10 lb.) force.
7 - 26 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(4) Remove the thermowrap from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BATTERY TRAY
REMOVAL
(1) Remove battery. Refer to Battery Removal and
Installation in this section.
(2) Remove two nuts to the rear and two bolts to
the front of the battery tray (Fig. 18).
(3) Slide battery tray out form under the air
cleaner assembly. Do not remove the air cleaner
assembly.
(4) Remove battery tray from vehicle.
INSTALLATION
For installation reverse the above procedures.
SPECIFICATIONS
BATTERY SPECIFICATIONS
COLD CRANK RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
±18É C (0É F).
RESERVE CAPACITY RATING
The length of time a battery can deliver 25 amps
and maintain a minimum terminal voltage of 10.5
volts at 27ÉC (80ÉF).TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp Bolt . . 135615 in.
lbs.
Battery Mount Fasteners....... 105610 in. lbs.
Fig. 18 Battery Tray Removal
1 ± BATTERY TRAY
2 ± LEFT STRUT TOWER
3 ± PDC
4 ± MOUNTING HOLES/SLOTS
5 ± COOLANT RESERVOIR
Load Test Cold
CrankingReserve
(Amps) Rating @
-18ÉC (0ÉF)Capacity
225 Amp 450 Amp 85 Minutes
PLBATTERY 8A - 11
REMOVAL AND INSTALLATION (Continued)

(3) Continuity should be observed between the
ground shell of the connector and the mounting hard-
ware on the vehicle antenna. The wheel well splash
shield must be removed for access to the antenna
that is mounted on load beam.
BENCH TEST FOR ANTENNA MALFUNCTION
It is also possible to check short or open circuits
with an ohmmeter or continuity light once the
antenna has been removed from the vehicle.
(1) Continuity should be present between the tip of
the mast and radio lead in (Fig. 2).
(2) No continuity should be observed or a very
high resistance of several megohms between the
ground shell of the connector and radio end pin.
(3) Continuity should be observed between the
ground shell of the connector and the mounting
bracket.Wiggle cable over its entire length to
reveal intermittent short or open circuits dur-
ing step 1, 2 and 3.
REMOVAL AND INSTALLATION
CD CHANGER
REMOVAL
(1) Disconnect and isolate the battery negative
cable (Fig. 3).
(2) Using a trim stick (special tool #C-4755), gently
pry out on CD changer bezel and remove.
Fig. 1 Antenna Test Points
1 ± TIP OF MAST TEST POINT
2 ± DISCONNECT TEST POINTS
3 ± RADIO END PIN TEST POINT
Fig. 2 Antenna Bench Test Points
1 ± TIP OF MAST
2 ± ANTENNA BODY
3 ± PLUG
4 ± CONNECTORS
5 ± RADIO LEAD IN
Fig. 3 Battery Negative Cable Remove/Install
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
PLAUDIO SYSTEM 8F - 7
DIAGNOSIS AND TESTING (Continued)

WINDSHIELD WIPER and WASHER SYSTEMS
TABLE OF CONTENTS
page page
WINDSHIELD WIPER SYSTEM................ 1WINDSHIELD WASHER SYSTEM.............. 8
WINDSHIELD WIPER SYSTEM
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
WIPER BLADES...........................1
DIAGNOSIS AND TESTING
WINDSHIELD WIPER CONDITIONS............2
WINDSHIELD WIPER MOTOR................3
WINDSHIELD WIPER/WASHER SWITCH........5
REMOVAL AND INSTALLATION
WINDSHIELD WIPER ARM(S)................5WINDSHIELD WIPER BLADE(S)..............5
WINDSHIELD WIPER BLADE ELEMENT........5
WINDSHIELD WIPER LINKAGE...............5
WINDSHIELD WIPER MODULE...............6
WINDSHIELD WIPER MOTOR................6
WINDSHIELD WIPER/WASHER SWITCH........6
CLEANING AND INSPECTION
WINDSHIELD WIPER BLADE(S)..............6
ADJUSTMENTS
WINDSHIELD WIPER ARM(S)................6
GENERAL INFORMATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M, PASSIVE
RESTRAINT SYSTEMS FOR STEERING WHEEL
REMOVAL AND INSTALLATION.
The windshield wipers will only operate with the
ignition switch in the ACCESSORY or IGNITION
RUN position. The wiper circuit is protected against
over loads by a fuse in the fuse block and a circuit
breaker within the wiper motor. This protects the cir-
cuitry of the wiper system and the vehicle. The wiper
motor has permanent magnet fields.
The intermittent wiper system, in addition to low
and high speed, has a delay mode and a pulse wipe
mode. The delay mode has a range of 1 to 15 seconds.
Pulse wipe is accomplished by momentarily moving
the stalk lever into the WASH position while the
wiper switch is in either OFF or DELAY position.
The wiper blades then sweep once or twice and
return to the previous wiper switch mode, OFF or
DELAY.The intermittent wiper function is integral to the
wiper switch. All electronics and relay are inside the
switch assembly.
The wiper system completes the wipe cycle when
the switch is turned OFF. The blades park in the
lowest portion of the wipe pattern.
The wiper switch also includes the MIST feature
which provides a single wipe when actuated.
DESCRIPTION AND OPERATION
WIPER BLADES
Wiper blades, exposed to the weather for a long
period of time, tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is suggested to
remove the accumulation of salt and road film. The
wiper blades, arms, and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the blades continue to
streak or smear, they should be replaced. The right
and left wipers are different blade lengths. The
driver side length is 550 mm and the passenger side
length is 475 mm. The blades should not be inter-
changed.
PLWINDSHIELD WIPER and WASHER SYSTEMS 8K - 1

kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 16) (Fig. 17).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 18).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 18).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
Fig. 16 Terminal Removal
1 ± CONNECTOR
2 ± FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
1 ± FROM SPECIAL TOOL KIT 6680
2 ± CONNECTOR
PL8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)