2000 DODGE NEON transmission

DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further. If
chatter persists:
(2) Check to see if clutch cable routing is correct
and operates smoothly.
(3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary.
CLASH±INTO±REVERSE COMPLAINTS
Certain NV T350 (A-578) manual transaxles are
equipped with a reverse brake. It prevents clash
when shifting into reverse, but only if the vehicle is
not moving. See Group 21, Transaxle for further
diagnosis.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.(2) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(3) Check the input shaft spline, clutch disc
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check for broken clutch cover diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.
CLUTCH INTERLOCK/UPSTOP SWITCH
The clutch interlock/upstop switch is an assembly
consisting of two switches: an engine starter inhibit
switch (clutch interlock) and a clutch pedal upstop
switch (Fig. 5). The switch assembly is located in the
clutch/brake pedal bracket assembly (Fig. 6), each
switch being fastened by four plastic wing tabs.
CLUTCH INTERLOCK SWITCH
Mechanical Test
(1) With the park brake set and the transaxleIN
NEUTRAL,turn the ignition key to the start posi-
tion. The engine starter should not crank with the
clutch pedal at rest (not depressed). If the starter
cranks, proceed to the electrical test to determine
whether the switch is defective or the circuit is
shorted. If the vehicle does not crank, proceed to the
next step.
(2) With the park brake set and the transaxleIN
NEUTRAL,fully depress the clutch pedal and turn
Fig. 5 Clutch Interlock/Upstop Switch
1 ± UPSTOP SWITCH
2 ± INTERLOCK SWITCH
3 ± CONNECTOR
PLCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)

COOLING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
COOLING SYSTEM........................1
COOLANT...............................2
COOLANT PERFORMANCE..................2
COOLANT RECOVERY SYSTEM..............3
ENGINE THERMOSTAT.....................3
RADIATOR..............................3
RADIATOR COOLING FAN MODULE...........3
COOLING SYSTEM PRESSURE CAP..........4
RADIATOR HOSES AND CLAMPS............5
WATER PUMP...........................5
AUTOMATIC TRANSMISSION OIL COOLER.....6
ACCESSORY DRIVE BELTS.................6
ENGINE BLOCK HEATER...................6
DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS..............7
ENGINE THERMOSTAT TESTING............14
ACCESSORY DRIVE BELT DIAGNOSIS........14
WATER PUMP DIAGNOSIS................15
COOLING SYSTEM FLOW CHECK...........15
ELECTRIC FAN MOTOR TEST...............15
COOLANT CONCENTRATION TESTING........15
TESTING COOLING SYSTEM FOR LEAKS.....15
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK...............16
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP.......................16
LOW COOLANT LEVEL AERATION...........17
DEAERATION...........................17
TEMPERATURE GAUGE INDICATION.........17
ENGINE BLOCK HEATER..................17
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE.........17COOLANTÐADDING ADDITIONAL...........18
COOLANT LEVELÐSERVICING.............18
COOLING SYSTEMÐDRAINING.............19
COOLING SYSTEMÐREFILLING............19
REMOVAL AND INSTALLATION
WATER PUMP..........................19
WATER PUMP INLET TUBE................20
ENGINE THERMOSTAT....................20
RADIATOR.............................21
RADIATOR DRAINCOCK...................22
COOLING FAN MODULE...................22
COOLANT RECOVERY CONTAINER..........23
ENGINE BLOCK HEATER..................24
ACCESSORY DRIVE BELTS................24
AUTOMATIC BELT TENSIONER & PULLEY....26
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE...................26
CLEANING AND INSPECTION
WATER PUMP..........................28
ACCESSORY DRIVE BELT INSPECTION.......28
COOLING SYSTEM CAP...................28
COOLING SYSTEM CLEANING..............28
RADIATOR FLUSHING....................28
REVERSE FLUSHING.....................29
CHEMICAL CLEANING....................29
ADJUSTMENTS
BELT TENSION..........................29
SPECIFICATIONS
COOLING SYSTEM CAPACITY..............30
TORQUE SPECIFICATIONS.................30
SPECIAL TOOLS
COOLING..............................30
DESCRIPTION AND OPERATION
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, and a water pump to
circulate the coolant. The engine cooling module may
consist of a radiator, electric fan motor, fan, shroud,
coolant reserve system, transmission oil cooler, hoses,clamps, air conditioning condenser and transmission
oil lines.
²When the Engine is cold: The thermostat is
closed and the cooling system has no flow through
the radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open
and the cooling system has flow through the radiator,
engine, heater system, and bypass.
PLCOOLING SYSTEM 7 - 1

protection. MopartAntifreeze or the equivalent is
recommended for best engine cooling without corro-
sion. When mixed only to a freeze point of -37ÉC
(-35ÉF) to -59ÉC (-50ÉF). If it looses color or becomes
contaminated, drain, flush, and replace with fresh
properly mixed solution.
COOLANT RECOVERY SYSTEM
This system works in conjunction with the radiator
pressure cap to utilize thermal expansion and con-
traction of the coolant to keep the coolant free of
trapped air. The system provides space for expansion
and contraction. Also, the system provides a conve-
nient and safe method for checking and adjusting the
coolant level at atmospheric pressure without remov-
ing the pressure cap. It also provides some reserve
coolant to compensate for minor leaks and evapora-
tion or boiling losses. All vehicles are equipped with
this system (Fig. 2).
Refer to Coolant Level Check, Deaeration, and
Pressure Cap sections for operation and service.
ENGINE THERMOSTAT
The engine thermostat is located on the front of
the engine (radiator side) in the thermostat housing/
engine outlet connector. The thermostat has an air
bleed (vent) located in the flange and a O-ring for
sealing incorporate on it. There is a relief in the ther-
mostat housing/outlet connector for the O-ring.
The engine thermostat is a wax pellet driven,
reverse poppet choke type. It is designed to provide
the fastest warm up possible by preventing leakage
through it and to guarantee a minimum engine oper-
ating temperature of 88 to 93ÉC (192 to 199ÉF). Also,
the thermostat will automatically reach wide open, to
accommodate unrestricted flow to the radiator astemperature of the coolant rises in hot weather to
around 104ÉC (220ÉF). Above this temperature the
coolant temperature is controlled by the radiator, fan,
and ambient temperatureÐnot the thermostat.
A thermostats primary purpose is to maintain
engine temperature in a range that will provide sat-
isfactory engine performance and emission levels
under all expected driving conditions. It also provides
hot water (coolant) for heater performance. It does
this by transferring heat from engine metal and
automatic transmission oil cooler (if equipped) to
coolant, moving this heated coolant to the heater core
and radiator, and then transferring this heat to the
ambient air.
RADIATOR
The radiator is a down-flow type (vertical tubes)
with design features that provide greater strength,
as well as sufficient heat transfer capabilities to keep
the engine coolant within operating temperatures.
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
The radiator has an aluminum core with plastic
tanks. Although stronger than brass, plastic tanks
are subject to damage by impact. Always handle radi-
ator with care.
RADIATOR COOLING FAN MODULE
The radiator cooling fan is a single speed electric
motor driven fan. The fan module includes an electric
motor, fan blade, and a support shroud that is
attached to the radiator (Fig. 3).
Fig. 2 Coolant Recovery System
1 ± RECOVERY HOSE
2 ± ENGINE COOLANT RECOVERY CONTAINER
3 ± PRESSURE CAP
Fig. 3 Radiator Fan
1 ± SCREWS
2 ± LOWER MOUNTS
3 ± FAN MOTOR ELECTRICAL CONNECTOR
PLCOOLING SYSTEM 7 - 3
DESCRIPTION AND OPERATION (Continued)

AUTOMATIC TRANSMISSION OIL COOLER
Oil coolers are internal oil to coolant type, mounted
in the radiator lower tank (Fig. 9). Rubber oil lines
feed the oil cooler and the automatic transmission.
Use only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses
are recommended. Tighten Oil Cooler Hose Clamps
to 2 N´m (18 in. lbs.).
ACCESSORY DRIVE BELTS
The accessory drive consist of two Poly-V type
drive belts (Fig. 10). One belt drives the generator,
the other drives the power steering pump and air
conditioning compressor (if equipped). The power
steering/air conditioning belt is tensioned by an auto-
matically controlled belt tensioner. The generator
belt is manually tensioned using an adjusting bolt
and a locking nut.
ENGINE BLOCK HEATER
The heater is mounted in a core hole (in place of a
core hole plug) in the engine block, with the heating
element immersed in coolant (Fig. 11). The engine
block heater is available as an optional accessory.
The heater is operated by ordinary house current
(110 Volt A. C.) through a power cord and connector
behind the radiator grille.
When in operation, the engine block heater can
provide easier engine starting and faster warm-up,
when vehicle is operated in areas having extremely
low temperatures.CAUTION: The power cord must be secured in its
retainer clips, and not positioned so it could con-
tact linkages or exhaust manifolds and become
damaged.
Fig. 9 Automatic Transmission Oil Cooler
1 ± CLAMPS
2 ± HOSES
Fig. 10 Accessory Drive Belts
1 ± GENERATOR BELT
2 ± AUTOMATIC BELT TENSIONER
3 ± POWER STEERING PUMP/A/C COMPRESSOR BELT
Fig. 11 Engine Block Heater
1 ± CORE PLUG
2 ± BLOCK HEATER
3 ± POWER CORD
7 - 6 COOLING SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

(3) Remove thermostat/engine outlet connector
bolts (Fig. 22).
(4) Remove thermostat and O-ring assembly.
INSTALLATION
(1) Clean all sealing surfaces.
(2) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align vent with
notch in cylinder head.
(3) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.).
(4) Install upper radiator hose.
(5) Connect the coolant recovery/reserve system
hose.
(6) Refill cooling system. Refer to procedure in this
section.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to procedure in
this section.
(3) Remove upper radiator hose from the radiator.
(4) Disconnect and cap automatic transmission
hoses, if equipped.(5) Disconnect cooling fan motor electrical connec-
tor.
(6) Remove cooling fan module retaining screws,
located on the top of the shroud (Fig. 23). Lift shroud
up and out of bottom shroud attachment clips sepa-
rating shroud from radiator.
(7) Remove the lower radiator hose.
(8) Remove upper radiator isolator bracket mount-
ing screws (Fig. 24). Disconnect the engine block
heater wire, if equipped.
(9) Remove the air conditioning condenser attach-
ing screws located at the front of the radiator, if
equipped (Fig. 25), then lean condenser forward.
NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.
Fig. 22 Thermostat/Engine Outlet Connector
1 ± PRESSURE CAP
2 ± THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
3 ± THERMOSTAT
4 ± O-RING
5 ± VENT FACING UP
Fig. 23 Fan Module Mounting
1 ± SCREWS
2 ± LOWER MOUNTS
3 ± FAN MOTOR ELECTRICAL CONNECTOR
Fig. 24 Radiator Mounting
1 ± UPPER RADIATOR HOSE
2 ± UPPER RADIATOR MOUNTS
PLCOOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)

(10) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Slide radiator down into position behind radia-
tor support (yoke).
(2) Attach air conditioning condenser to radiator, if
equipped (Fig. 25), with four mounting screws.
Tighten screws to 5.4 N´m (50 in. lbs.). Then seat the
radiator assembly lower rubber isolators into the
mounting holes provided in the lower crossmember.
(3) Install and tighten radiator isolator mounting
bracket screws to 10 N´m (90 in. lbs.) (Fig. 24). The
radiator should have clearance to move up, approxi-
mately 5±8 mm (0.20±0.31 in.) after assembled.
(4) Install lower radiator hose. Align the hose and
position the clamp so it will not interfere with engine
components.
(5) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 2 N´m (18 in. lbs.).
(6) Slide fan module down into clip(s) on lower
radiator flange (Fig. 23). Install retaining screws and
tighten to 7.5 N´m (65 in. lbs.).
(7) Connect the cooling fan motor electrical connec-
tor.
(8) Install upper radiator hose. Align the hose and
position the clamp so they will not interfere with the
engine or the hood.
(9) Connect negative cable to battery.
(10) Fill cooling system with coolant. Refer to pro-
cedure in this section.
(11) Operate engine until it reaches normal operat-
ing temperature. Check cooling system and auto-
matic transmission for correct fluid levels.
RADIATOR DRAINCOCK
REMOVAL
(1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 26) from
the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening.
(2) Tighten the draincock stem by turning clock-
wise to 2.0-2.7 N´m (18-25 in. lbs.).
COOLING FAN MODULE
All models use a single speed electric motor driven
cooling system fan. The fan module includes a motor,
fan blade, and support shroud. The module is fas-
tened to the radiator by screws.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain cooling system below upper radiator hose
level. Refer to procedure in this section.
(3) Remove upper radiator hose from radiator (Fig.
27).
(4) Disconnect fan module electrical connector.
(5) Remove fan module screws from radiator (Fig.
28).
(6) Lift fan shroud up and out of lower shroud
attachment clips.
(7) Refer to Disassembly and Assembly in this sec-
tion for fan module sub-component service proce-
dures.
Fig. 25 A/C Condenser to Radiator Mounting Screws
1 ± AIR CONDITIONING CONDENSER TO RADIATOR
MOUNTING SCREWS
2 ± LOWER ISOLATOR MOUNTS
Fig. 26 Draincock
1 ± DRAIN COCK BODY
2 ± DRAIN COCK HOUSING
7 - 22 COOLING SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE SPECIFICATIONSSPECIAL TOOLS
COOLING
6.2 Liters (6.5 qts.)
CAPACITY, Includes Heater and Coolant Reserve
System
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
A/C Condenser to RadiatorÐ
Screws5.4 Ð 50
Automatic Belt Tensioner
PulleyÐBolt27 20 Ð
Coolant Recovery ContainerÐ
Nut/Screw4Ð35
Fan Module to RadiatorÐ
Screws7.2 Ð 65
Fan Motor to ShroudÐScrews 3.8 Ð 34
Fan Blade to Motor ShaftÐ
Nut3.8 Ð 34
In Rush Current SupressorÐ
Screw2.6 Ð 23
Generator MountingÐPivot
Bolt54 40 Ð
Generator MountingÐLocking
Nut54 40 Ð
Radiator (Cooling Module) to
BodyÐScrews10 Ð 90
Thermostat Housing/Water
Outlet ConnectorÐScrews12 Ð 105
Transmission HoseÐClamps 2 Ð 18
Water Pump to Engine
BlockÐBolts12 Ð 105
Water Pump Inlet Tube to
Engine BlockÐBolts12 Ð 105
Hose Clamp Pliers 6094
Coolant Refractometer 8286
7 - 30 COOLING SYSTEMPL

STARTING SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
SUPPLY CIRCUIT AND CONTROL CIRCUIT.....1
DESCRIPTION AND OPERATION
STARTER MOTOR.........................1
DIAGNOSIS AND TESTING
CONTROL CIRCUIT........................2
FEED CIRCUIT RESISTANCE................3
FEED CIRCUIT...........................5STARTING SYSTEM.......................6
REMOVAL AND INSTALLATION
SAFETY SWITCHES.......................8
STARTER MOTOR.........................8
STARTER RELAY.........................8
SPECIFICATIONS
STARTER MOTOR.........................9
TORQUE................................9
GENERAL INFORMATION
INTRODUCTION
The starting system (Fig. 1) and (Fig. 2) has:
²Ignition switch
²Starter relay
²Park/Neutral Starting Back-Up Lamp Switch
with automatic transmissions
²Clutch Interlock/Upstop Switch with manual
transmissions
²Powertrain Control Module (PCM) for double
start over ride
²Wiring harness
²Battery
²Starter motor with an integral solenoid
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The Powertrain Control Module (PCM) controls a
double start over ride safety that does not allow thestarter to be engaged if the engine is already run-
ning.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate cir-
cuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
DESCRIPTION AND OPERATION
STARTER MOTOR
The starter is a permanent magnet starter motor.
The fields have six permanent magnets. A planetary
gear train transmits power between starter motor
and pinion shaft. The starter provides mechanical
torque to rotate the crankshaft at an RPM (crank
speed) necessary for self-sustained spark/ignition.Fig. 1 Starting System Components - Automatic
Fig. 2 Starting System Components - Manual
PLSTARTING SYSTEMS 8B - 1