2000 DODGE NEON spark

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)

REMOVAL
(1) Remove brake booster hose and electrical con-
nector from holders on end of cylinder head cover
and reposition.
(2) Disconnect electrical connectors from camshaft
position sensor.
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft (Fig. 14).
INSTALLATION
The target magnet has two locating dowels that fit
into machined locating holes in end of the camshaft.
(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3.4 N´m (30 in. lbs.)
torque.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 9 N´m (80 in. lbs.) torque.
(3) Place brake booster hose and electrical harness
in holders on end of valve cover.
(4) Attach electrical connectors to camshaft posi-
tion sensor.
Fig. 11 Electronic Ignition Coil Pack
1 ± IGNITION COILS
2 ± SPARK PLUG CABLE
3 ± SPARK PLUG INSULATOR
Fig. 12 Power Distribution Center (PDC)
Fig. 13 Camshaft Position Sensor Location
Fig. 14 Target Magnet Removal/Installation
1 ± TARGET MAGNET
2 ± MOUNTING BOLT
3 ± REAR OF CYLINDER HEAD
PLIGNITION SYSTEM 8D - 7
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT POSITION SENSOR
The crankshaft position sensor mounts to the
engine block behind the generator, just above the oil
filter (Fig. 15).
REMOVAL
(1) Disconnect electrical connector from crankshaft
position sensor.
(2) Remove sensor mounting screw. Remove sensor.
INSTALLATION
(1) Install sensor. Install sensor mounting screw
and tighten.
(2) Connect electrical connector to crankshaft posi-
tion sensor.
KNOCK SENSOR
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 16).
REMOVAL
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
IGNITION SWITCH
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig.
17). For ignition switch terminal and circuit identifi-
cation, refer to the Wiring Diagrams sections.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Place key cylinder in RUN position. Through
the hole in the lower shroud, depress lock cylinder
retaining tab and remove key cylinder (Fig. 18).
(3) Remove upper and lower shrouds from steering
column.
Fig. 15 Crankshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± GENERATOR
3 ± OIL FILTER
Fig. 16 Knock Sensor
Fig. 17 Ignition SwitchÐViewed From Below
Column
1 ± IGNITION SWITCH
2 ± LOCK CYLINDER HOUSING
3 ± RETAINING TABS
8D - 8 IGNITION SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

TORQUE SPECIFICATION
DESCRIPTION TORQUE
Camshaft Position Sensor Screw.......... 9N´m
(80 in. lbs.)
SOHC Cam Magnet/Target . . . 3.4 N´m (30 in. lbs.)
Crankshaft Position Sensor Screw........ 9N´m
(80 in. lbs.)
Coolant Temp. Sensor.....18.6 N´m (165 in. lbs.)
Ignition Coil to Cyl. Head . . 11.9 N´m (105 in. lbs.)
Knock Sensor.............. 10N´m(90in.lbs.)
MAP/IAT Sensor Plastic Manifold......... 2N´m
(20 in. lbs.)
Spark Plugs................ 28N´m(20ft.lbs.)
SPARK PLUG CABLE RESISTANCEÐSOHC
SPARK PLUG
Engine Spark Plug Gap Thread Size
2.0L RC9YC 0.033 TO 0.038 14mm (3/4 in.) reach
IGNITION COIL
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 11,500 to 13,500 Ohms
Diamond (copper towers) 0.53 to 0.65 Ohms 10,900 to 14,700 Ohms
CABLE RESISTANCE
#1,#4 3500 ohmsÐ 4900 ohms
#2,#3 2950 ohmsÐ 4100 ohms
Coil Polarity
Coil Polarity
PLIGNITION SYSTEM 8D - 11
SPECIFICATIONS (Continued)

AUDIO SYSTEM
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION...............1
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES......1
TESTING................................1
BENCH TEST FOR ANTENNA MALFUNCTION...7REMOVAL AND INSTALLATION
CD CHANGER............................7
FRONT DOOR SPEAKER....................8
INSTRUMENT PANEL SPEAKER(S)...........8
MAST and ANTENNA ASSEMBLY.............8
RADIO..................................9
REAR SHELF SPEAKER(S).................10
GENERAL INFORMATION
INTRODUCTION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with the vehicle.
The vehicles are equipped with an Interior (Igni-
tion Off Draw) fuse in the Power Distribution Center
located in the engine compartment. After the Interior
(IOD) fuse or battery has been disconnected the clock
will require resetting. The radio station presets have
a nonvolatile memory and will retain the preset sta-
tions after a battery disconnect.
The available radio options are:
²AM/FM Stereo Cassette w/Clock
²AM/FM/CD
²AM/FM Cassette w/CD Changer Controls and
Display
²CD/4 Disc Changer - In-Dash (used w/Radio CD
Changer Controls)
DESCRIPTION AND OPERATION
INTERFERENCE ELIMINATION
The radio utilizes a ground wire plugged on to a
blade terminal and is bolted to the radio chassis.
Both connector and terminal should be securely
attached. The engine has two separate ground straps
to suppress ignition noise which may interfere with
radio reception.
²Left engine mount clip on strap
²Engine to shock tower reinforcement
Inductive type spark plug cables in the high ten-
sion circuit of the ignition system complete the inter-
ference suppression. Faulty or deteriorated spark
plug wires should be replaced.
DIAGNOSIS AND TESTING
AUDIO DIAGNOSTIC TEST PROCEDURES
CAUTION: The CD player will only operate between
approximate temperatures of -23ÉC and +65ÉC (-10ÉF
and +145ÉF).
Whenever a radio malfunction occurs;
(1) First check FUSES:
(a) Power Distribution Center (PDC), Interior
lamp fuse, M1 - Radio Memory Feed
(b) Fuse Block:
(I) Fuse 12, Illumination in the fuse block
(II) Fuse 16, Ignition feed in the fuse block
NOTE: The vehicles are shipped with the INTERIOR
LAMP fuse disconnected.
(2) Verify, the radio wire harness are properly con-
nected before starting normal diagnosis and repair
procedures. Refer to Audio Diagnostic Charts and/or
Group 8W, Wiring Diagrams, Radio Section.
TESTING
The antenna has a short cable which connects into
the instrument panel harness. The connection is
made on the right side of the instrument panel.
Antenna performance may be tested by substitut-
ing a known good antenna. It is also possible to
check short or open circuits with an ohmmeter or
continuity light once the antenna cable is discon-
nected from the radio as follows:
(1) Continuity should be present between the
antenna mast and radio end pin of antenna cable
plug (Fig. 1).
(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.
PLAUDIO SYSTEM 8F - 1

WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 2) is used to indicate this. When han-
dling any component with this symbol comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective
packing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: - Most of the electrical components used
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance rating. In addi-
tion, make sure the power is disconnected from the
circuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 3). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly check the following items.
Fig. 2 Electrostatic Discharge Symbol
Fig. 3 Probing Tool
1 ± SPECIAL TOOL 6801
2 ± PROBING END
8W - 01 - 8 8W - 01 GENERAL INFORMATIONPL
DESCRIPTION AND OPERATION (Continued)

CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean all debris/rust from inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with MopartStud and Bearing Mount Adhesive.
Make certain the new plug is cleaned of all oil or
grease. Using a proper driver, drive plug into hole so
that the sharp edge of the plug is at least 0.5 mm
(0.020 inch.) inside the lead in chamfer (Fig. 3).
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
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 it's
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-ing to these standards, refer to Engine Diagnosis in
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 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. Refer to
Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
Fig. 2 Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
Fig. 3 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
PLENGINE 9 - 3
GENERAL INFORMATION (Continued)

²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 5). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. Thefollowing is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 5). In addition, suspect areas can be
checked by placing plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the scale pro-
vided on the package. Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications.Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
Fig. 6 Clearance Measurement
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)