2000 DODGE NEON Service Repair Manual

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

BATTERY
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION..........................1
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD).........2
CHARGING TIME REQUIRED................2
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR.........3
BATTERY IGNITION OFF DRAW (IOD).........4
BATTERY LOAD TEST......................6
BATTERY OPEN CIRCUIT VOLTAGE...........7
SERVICE PROCEDURES
BATTERY CHARGING......................7CHARGING COMPLETELY DISCHARGED
BATTERY..............................8
VISUAL INSPECTION......................9
REMOVAL AND INSTALLATION
BATTERY...............................10
BATTERY THERMOWRAP..................10
BATTERY TRAY..........................11
SPECIFICATIONS
BATTERY SPECIFICATIONS................11
TORQUE...............................11
GENERAL INFORMATION
INTRODUCTION
The battery (Fig. 1) stores, stabilizes, and delivers
electrical current to operate various electrical sys-
tems in the vehicle. The determination of whether a
battery is good or bad is made by its ability to accept
a charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid
in the electrolyte is measured as specific gravity
using a hydrometer. The original equipment (OE)
battery is equipped with a hydrometer (test indica-
tor) built into the battery cover. The specific gravity
indicates the battery's state-of-charge. The OE bat-
tery is sealed and water cannot be added.
The battery is vented to release gases that are cre-
ated when the battery is being charged and discharged.
The battery top, posts, and terminals should be cleaned
when other under hood maintenance is performed.
When the electrolyte level is below the top of the
plates, Yellow/Clear in the test Indicator, the battery
must be replaced. The battery must be completely
charged, and the battery top, posts, and cable clamps
must be cleaned before diagnostic procedures are per-
formed.
Fig. 1 Battery Location
1 ± BATTERY
2 ± LEFT STRUT TOWER
3 ± PDC
4 ± THROTTLE BODY
5 ± AIR CLEANER HOUSING
PLBATTERY 8A - 1

DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
A completely normal vehicle will have a small
amount of current drain on the battery with the key
out of the ignition. It can range from 4 to 10 milli-
amperes after all the modules time out. If a vehicle
will not be operated for approximately a 20 days, the
IOD fuse should be disconnected to minimize the
vehicle electrical drain on the battery. The IOD fuse
is located in the Power Distribution Center (PDC).
Refer to the PDC cover to locate the proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1ÉC (30ÉF) BATTERY. PER-
SONAL INJURY MAY RESULT.
The time required to charge a battery will vary
depending upon the following factors.
SIZE OF BATTERY
A completely discharged large heavy-duty battery
may require more recharging time than a completely
discharged small capacity battery, refer to Battery
Charging Timetable for charging times.
TEMPERATURE
A longer time will be needed to charge a battery at
-18ÉC (0ÉF) than at 27ÉC (80ÉF). When a fast charger
is connected to a cold battery, current accepted by
battery will be very low at first. In time, the battery
will accept a higher rate as battery temperature
warms.
CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a
charger that can supply 20 amperes or more.
STATE OF CHARGE
A completely discharged battery requires more
charging time than a partially charged battery.
NOTE: Do not attempt to recharge a battery with a
yellow/clear test indicator.
Electrolyte is nearly pure water in a completely
discharged battery. At first, the charging current
amperage will be low. As water is converted back to
sulfuric acid inside the battery, the current amp rate
will rise. Also, the specific gravity of the electrolyte
will rise, bringing the green ball (Fig. 2) into view at
approximately 75 percent state-of-charge.
BATTERY CHARGING TIMETABLE
CHARGING
AMPERAGE5
AMPERES10
AMPERES20
AMPERES
OPEN
CIRCUIT
VOLTAGEHOURS CHARGING AT 21É C (70É F)
12.25 TO
12.496 HOURS 3 HOURS 1.5 HOURS
12.00 TO
12.2410 HOURS 5 HOURS 2.5 HOURS
10.00 TO
11.9914 HOURS 7 HOURS 3.5 HOURS
*BELOW
10.0018 HOURS 9 HOURS 4.5 HOURS
*REFER TO CHARGING A COMPLETELY DISCHARGED
BATTERY
Fig. 2 Reading Test Indicator
1 ± TEST INDICATOR/STATE OF CHARGE
2 ± REPLACE BATTERY
3 ± CLEAR
4 ± BLACK
5 ± GREEN
8A - 2 BATTERYPL

DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR
USING TEST INDICATOR
The Test Indicator (Fig. 2), (Fig. 3) and (Fig. 4)
measures the specific gravity of the electrolyte. Spe-
cific Gravity (SG) of the electrolyte will show state-
of-charge (voltage). The test indicator WILL NOT
show cranking capacity of the battery. Refer to Bat-
tery Load Test for more information. Look into the
sight glass (Fig. 2), (Fig. 4) and note the color of the
indicator. Refer to the following description of colors:
NOTE: GREEN = 75 to 100% state-of-charge
The battery is adequately charged for further test-
ing and may be returned to use. If the vehicle will
not crank for a maximum 15 seconds, refer to BAT-
TERY LOAD TEST in this Group for more informa-
tion.
NOTE: BLACK OR DARK=0to75%state-of-chargeThe battery is INADEQUATELY charged and must
be charged until green dot is visible, (12.4 open cir-
cuit volts or greater) before the battery is tested or
returned to use. Refer to Causes of Battery Discharg-
ing in this group for more information.
NOTE: CLEAR COLOR = Replace Battery
WARNING: DO NOT CHARGE, ASSIST BOOST,
LOAD TEST, OR ADD WATER TO THE BATTERY
WHEN CLEAR COLOR DOT IS VISIBLE. PERSONAL
INJURY MAY OCCUR.
A clear color dot shows electrolyte level in battery
is below the test indicator (Fig. 2). Water cannot be
added to a maintenance free battery. The battery
must be replaced. A low electrolyte level may be
caused by an over charging condition. Refer to Gen-
erator Test Procedures on Vehicle.
CAUSES OF BATTERY DISCHARGING
It is normal to have a small 5 to 25 milliamperes
continuous electrical draw from the battery. This
draw will take place with the ignition in the OFF
position, and the courtesy, dome, storage compart-
ments, and engine compartment lights OFF. The con-
tinuous draw is due to various electronic features or
accessories that require electrical current with the
ignition OFF to function properly. When a vehicle is
not used over an extended period of approximately 20
days the IOD fuse should be pulled. The fuse is
located in the power distribution center. Disconnec-
tion of this fuse will reduce the level of battery dis-
charge. Refer to the Battery Diagnosis and Testing
table, and to the proper procedures.
Fig. 3 Battery Construction and Test Indicator -
Typical
1 ± POSITIVE POST
2 ± VENT
3 ± TEST INDICATOR
4 ± VENT
5 ± NEGATIVE POST
6 ± PLATE GROUPS
7 ± ELECTROLYTE LEVEL
8 ± GREEN BALL
9 ± MAINTENANCE FREE BATTERY
Fig. 4 Test Indicator - Typical
1 ± SIGHT GLASS
2 ± PLASTIC TUBE
3 ± GREEN BALL
4 ± BATTERY TOP
PLBATTERY 8A - 3

BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
CHECK FOR POSSIBLE
DAMAGE TO BATTERY AND
CLEAN BATTERY.(1) LOOSE BATTERY POST,
CRACKED BATTERY COVER
OR CASE, LEAKS OR ANY
OTHER PHYSICAL
(2) BATTERY OK.(1) REPLACE BATTERY
(2) CHECK STATE OF CHARGE.
REFER TO TEST INDICATOR.
TEST INDICATOR
CHECK CHARGE EYE COLOR(1) GREEN
(2) BLACK
(3) CLEAR(1) BATTERY IS CHARGED.
PERFORM BATTERY 0PEN
CIRCUIT VOLTAGE TEST
(2) PERFORM BATTERY
CHARGING PROCEDURE.
(3) REPLACE BATTERY.
BATTERY OPEN CIRCUIT
VOLTAGE TEST(1) BATTERY IS ABOVE 12.40
VOLTS
(2) BATTERY IS BELOW 12.40
VOLTS.(1) PERFORM THE BATTERY LOAD
TEST.
(2) PERFORM BATTERY
CHARGING PROCEDURE.
BATTERY CHARGING (1) BATTERY ACCEPTED
CHARGE.
(2) BATTERY WILL NOT
ACCEPT CHARGE(1) ENSURE THAT THE INDICATOR
EYE IS GREEN AND PERFORM
BATTERY 0PEN CIRCUIT VOLTAGE
TEST
(2) PERFORM CHARGING A
COMPLETELY DISCHARGED
BATTERY.
BATTERY LOAD TEST (1) ACCEPTABLE MINIMUM
VOLTAGE.
(2) UNACCEPTABLE MINIMUM
VOLTAGE(1) BATTERY IS OK TO PUT IN
USE, PERFORM BATTERY
IGNITION OFF DRAW TEST.
(2) REPLACE BATTERY AND
PERFORM BATTERY IGNITION OFF
DRAW TEST.
CHARGING A COMPLETELY
DISCHARGED BATTERY(1) BATTERY ACCEPTED
CHARGE.
(2)BATTERY WILL NOT
ACCEPT CHARGE.(1) ENSURE THAT THE INDICATOR
EYE IS GREEN AND PERFORM
BATTERY 0PEN CIRCUIT VOLTAGE
TEST.
(2) REPLACE BATTERY.
IGNITION OFF DRAW TEST (1) IOD IS 5-25
MILLIAMPERES.
(2) IOD EXCEEDS 25
MILLIAMPERES.(1) VEHICLE IS NORMAL.
(2) ELIMINATE EXCESS IOD DRAW.
ABNORMAL BATTERY DISCHARGING
²Corroded battery posts, cables or terminals.
²Loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system due to equipment or accessories
installed after delivery.
²Slow driving speeds in heavy traffic conditions
or prolonged idling with high-amperage electrical
systems in use.²Defective electrical circuit or component causing
excess Ignition Off Draw (IOD). Refer to Battery
Ignition Off Draw (IOD).
²Defective charging system.
²Defective battery.
BATTERY IGNITION OFF DRAW (IOD)
High current draw on the battery with the ignition
OFF will discharge a battery. After a dead battery is
recharged, the vehicle ignition off draw (IOD) should
8A - 4 BATTERYPL
DIAGNOSIS AND TESTING (Continued)

be checked. To determine if a high current draw con-
dition exists first check the vehicle with a test lamp.
(1) Verify that all electrical accessories are OFF.
²Remove key from ignition switch
²Turn off all lights
²Trunk lid is closed
²Engine compartment hood lamp is disconnected
or lamp removed
²Map lamp on rear view mirror
²Glove box door is closed
²Sun visor vanity lights are OFF
²All doors are closed
²Allow the ignition key lamp system to time out
in approximately 30 seconds, if equipped.
(2) Disconnect battery negative cable (Fig. 5).
(3) Connect a 12 Volt test lamp, with a cold resis-
tance of 5-7 ohms, between the battery negative cable
clamp and the negative post (Fig. 6). If test lamp
goes out system is OK. If test lamp lights and stays
ON, go to Test Lamp Stays ON procedure.
TEST LAMP STAYS ON
There is either a short circuit or a fault in an elec-
tronic module. Two fuses in the Power Distribution
Center (PDC) feed the modules with ignition off
draw.
²Interior lamps fuse (10 Amp) (IOD) PDC
²Fuel pump fuse (20 Amp) in PDC.
(1) Remove interior lamp and fuel pump fuses. By
removing these fuses all ignition off draw from thevehicle electronics will be disconnected. The test
lamp should go out. If test lamp goes out go to Step
2. If test lamp does not go out there is a current
draw or short circuit. Refer to Group 8W, Wiring Dia-
grams.
(2) Install the fuel pump fuse. If test lamp lights,
there is a current draw or short circuit in the A14
wiring circuit feed.
(a) Disconnect Powertrain Control Module.
(b) If test lamp goes out, replace Powertrain
Control Module.
(c) If test lamp does not go out, there is a cur-
rent draw or short circuit in the A14 circuit feed.
Refer to Group 8W, Wiring Diagrams.
(3) Install the interior lamp fuse. If test lamp
lights, there is a current draw or short circuit in the
M01 circuit. Refer to Group 8W, Wiring Diagrams. If
test lamp stays out, go to Step 4.
(4) Use a multi-meter that has at least a range of
200 milliamperes. Install meter between the battery
negative cable and battery negative post (Fig. 7).
Carefully remove the test lamp without disconnecting
the meter. After all modules time-out the total vehi-
cle IOD should be less than 10 milliamperes. If igni-
tion off draw is more than 10 milliamperes go to Step
5.
(5) Remove both fuses from the Power Distribution
Center:
²Fuel pump fuse (20 Amp)
²Interior lamps fuse (10 Amp)
(6) If there is any reading with fuses removed
there is a current draw or short circuit in the wiring.
Fig. 5 Disconnect and Isolate Battery Negative
Cable
1 ± NEGATIVE CABLE
2 ± NEGATIVE BATTERY POST
Fig. 6 Ignition OFF (IOD) Test
1 ± NEGATIVE TERMINAL
2 ± 12 VOLT TEST LIGHT
3 ± PDC
4 ± AIR CLEANER HOUSING
5 ± NEGATIVE BATTERY POST
PLBATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued)

Refer to Group 8W, Wiring Diagrams. If OK go to
Step 7.
(7) Install interior lamp fuse. After installing fuse,
the current can reach 250 milliamperes. After time-
out the reading should not exceed 8 milliamperes. If
NOT OK go to Step 8. If OK go to Step 9.
²Ignition key lamp system
²Radio
²Remote keyless entry module, if equipped
(8) Disconnect radio and ignition switch key lamp
one component at time, to see if any component is at
fault. If the high reading is not eliminated there is a
short circuit in the wiring. Refer to Group 8W, Wir-
ing Diagrams.
CAUTION: Always disconnect the meter before
opening a door.
(9) Remove interior lamps fuse and install the fuel
pump fuse. The reading should be between 1-3 milli-
amperes. If reading is higher than 3 milliamperes:
(a) Disconnect Powertrain Control Module.
(b) If reading drops to zero, replace Powertrain
Control Module.
(c) If reading remains the same there is a cur-
rent draw or short circuit in the A14 circuit. Refer
to Group 8W, Wiring Diagrams.
BATTERY LOAD TEST
A fully charged battery must have cranking capac-
ity, to provide the starter motor and ignition system
enough power to start the engine over a broad range
of ambient temperatures. A battery load test will ver-
ify the actual cranking capability of the battery.WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY
RESULT.
(1) Remove both battery cables, negative cable
first. The battery top, cables and posts should be
clean. If green dot is not visible in indicator, charge
the battery. Refer to Battery Charging Procedures in
this group.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 8). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 9).
(3) Allow the battery to stabilize for 2 minutes,
and then verify open circuit voltage.
Fig. 7 Milliampere Meter Connection
1 ± NEGATIVE TERMINAL
2 ± MILLIAMPERE METER
3 ± PDC
4 ± AIR CLEANER HOUSING
5 ± NEGATIVE BATTERY POST
Fig. 8 Volt-Ammeter Load Tester Connections -
Typical
1 ± INDUCTION AMPMETER CLAMP
2 ± NEGATIVE CLAMP
3 ± POSITIVE CLAMP
Fig. 9 Remove Surface Charge From Battery
8A - 6 BATTERYPL
DIAGNOSIS AND TESTING (Continued)

(4) Rotate the load control knob on the tester to
maintain 50% of the battery cold crank rating for 15
seconds (Fig. 10). Record the loaded voltage reading
and return the load control to off. Refer to the Bat-
tery Specifications at the rear of this group.
(5) Voltage drop will vary according to battery
temperature at the time of the load test. Battery
temperature can be estimated by the temperature of
exposure over the preceding several hours. If the bat-
tery has been charged or boosted a few minutes prior
to the test, the battery would be slightly warmer.
Refer to the Battery Load Test Temperatures table
for proper loaded voltage reading:
(6) If battery passes load test, it is in good condi-
tion and further tests are not necessary. If it fails
load test, it should be replaced.
BATTERY OPEN CIRCUIT VOLTAGE
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a batteryhas open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 8). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 9).
(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 11).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity. Refer to Battery Open Circuit
Voltage table.
SERVICE PROCEDURES
BATTERY CHARGING
A battery is considered fully charged when it will
meet all the following requirements.
²It has an open circuit voltage charge of at least
12.4 volts. Refer to the Battery Open Circuit Voltage
table in this section.
Fig. 10 Load 50% Cold Crank Rating
BATTERY LOAD TEST TEMPERATURES
MINIMUM
VOLTAGETEMPERATURE
ÉF ÉC
9.6 VOLTS 70É AND
ABOVE21É AND
ABOVE
9.5 VOLTS 60É 16É
9.4 VOLTS 50É 10É
9.3 VOLTS 40É 4É
9.1 VOLTS 30É -1É
8.9 VOLTS 20É -7É
8.7 VOLTS 10É -12É
8.5 VOLTS 0É -18É
Fig. 11 Testing Open Circuit Voltage
BATTERY OPEN CIRCUIT VOLTAGE
OPEN CIRCUIT VOLTS CHARGE PERCENTAGE
11.7 VOLTS OR LESS 0%
12.0 VOLTS 25%
12.2 VOLTS 50%
12.4 VOLTS 75%
12.6 VOLTS OR MORE 100%
PLBATTERY 8A - 7
DIAGNOSIS AND TESTING (Continued)