2000 DODGE NEON coolant level

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............8W-42
A/C Compressor Clutch.................8W-42
A/C Cycling Switch....................8W-42
A/C Heater Blower Motor...............8W-42
A/C Heater Control....................8W-42
A/C Pressure Switches..................8W-42
Airbag Control Module.................8W-43
Airbags.............................8W-43
Antenna.............................8W-47
Automatic Shut Down Relay.............8W-30
Back-Up Lamp Switch..................8W-51
Back-Up Lamps.......................8W-51
Battery.............................8W-20
Blower Motor Resistor Block.............8W-42
Brake Lamp Switch....................8W-30
Brake Shift Interlock Solenoid...........8W-30
Brake Warning Indicator Switch..........8W-40
Camshaft Position Sensor...............8W-30
Cargo Lamp..........................8W-44
Center High Mounted Stop Lamp.........8W-51
Center Stack Lamp....................8W-44
Cigar Lighter/Power Outlet..............8W-41
Circuit Breakers (FB)..................8W-11
City Lamps..........................8W-50
Clockspring.....................8W-33, 41, 43
Clutch Interlock Switch.................8W-30
Combination Flasher...................8W-52
Controller Anti-Lock Brake..............8W-35
Crankshaft Position Sensor..............8W-30
Data Link Connector...................8W-30
Decklid Release Switch.................8W-44
Decklid Solenoid......................8W-61
Diode No. 1..........................8W-42
Dome Lamp..........................8W-44
Dome Lamp/Intrusion Sensor............8W-44
Door Ajar Switches....................8W-40
Door Lock Motors.....................8W-61
Engine Coolant Temperature Sensor.......8W-30
Engine Oil Pressure Switch..............8W-30
Engine Starter Motor Relay.............8W-21
Engine Starter Motor..................8W-21
Fog Lamps........................8W-50, 51
Front Fog Lamp Switch.................8W-50
Fuel Injectors........................8W-30
Fuel Pump Module....................8W-30
Fuel Pump Relay......................8W-30
Fuel Tank...........................8W-30
Fuses (FB)...........................8W-11
Fuses (PDC).........................8W-10
Fuse Block...........................8W-11
Fusible Link A11...................8W-20, 21
Grounds.............................8W-15Component Page
Generator...........................8W-20
Glove Box Lamp/Switch.................8W-44
Headlamp Beam Select..............8W-40, 50
Headlamp Leveling Motors..............8W-50
Headlamp Leveling Switch Illumination....8W-50
Headlamp Leveling Switch..............8W-50
Headlamp Switch...................8W-50, 51
Headlamps..........................8W-50
Horns..............................8W-41
Horn Relay..........................8W-41
Horn Switch.........................8W-41
Hood Ajar Switch......................8W-39
Idle Air Control Motor..................8W-30
Ignition Coil.........................8W-30
Ignition Switch.......................8W-10
Indicators...........................8W-40
Indicator Drivers......................8W-40
Inlet Air Temperature Sensor............8W-30
Instrument Cluster....................8W-40
Instrument Panel Drivers...............8W-40
Knock Sensor.........................8W-30
Leak Detection Pump..................8W-30
License Lamps........................8W-51
Manifold Absolute Pressure Sensor........8W-30
Map/Reading Lamps...................8W-44
Multi- Function Switch.........8W-40, 50, 51, 52
Noise Suppressor......................8W-30
Oxygen Sensors.......................8W-30
Park Brake Switch....................8W-40
Park/Neutral Position Switch............8W-51
Park/Turn Signal Lamps................8W-52
Power Distribution Center...............8W-10
Power Mirror Switch...................8W-62
Power Steering Pressure Switch..........8W-30
Powertrain Control Module..............8W-30
PRNDL Lamp........................8W-44
Proportional Evap/Purge Solenoid.........8W-30
Radiator Fan Motor....................8W-42
Radiator Fan Relay....................8W-42
Radio...............................8W-47
Rear Window Defogger Switch...........8W-48
Rear Window Defogger.................8W-48
Remote Keyless Entry Module............8W-39
Repeater Lamps......................8W-52
Seat Belt Switch......................8W-40
Sentry Key Immobilizer Module..........8W-39
Side Marker Lamps....................8W-50
Siren...............................8W-39
Speakers............................8W-47
Splice Information.....................8W-70
Sunroof Control Module................8W-64
Sunroof Motor........................8W-64
PL8W - 02 COMPONENT INDEX 8W - 02 - 1

8W-40 INSTRUMENT CLUSTER
Component Page
A/C Heater Control..................8W-40-10
Airbag Control Module................8W-40-6
Brake Warning Indicator..............8W-40-11
Brake Warning Indicator Switch........8W-40-5
Center Stack Lamp..................8W-40-10
Circuit Breaker No. 2 (FB)............8W-40-12
Combination Flasher................8W-40-3, 4
Controller Anti-Lock Brake.............8W-40-5
Data Link Connector.................8W-40-5
Dome Lamp........................8W-40-9
Dome Lamp/Intrusion Sensor...........8W-40-9
Driver Door Ajar Switch.............8W-40-7, 8
Engine Coolant Temperature Sensor.....8W-40-5
Engine Oil Pressure Switch............8W-40-5
Front Fog Lamp Switch..............8W-40-14
Fuel Pump Module...................8W-40-6
Fuse 1 (FB).......................8W-40-3, 4
Fuse 10 (FB)........................8W-40-2
Fuse 11 (FB)........................8W-40-2
Fuse 13 (PDC)......................8W-40-2
Fuse 15 (FB)........................8W-40-2
Fuse 15 (PDC).....................8W-40-3, 4
Fuse 19 (FB).......................8W-40-13
Fuse 20 (FB).......................8W-40-14
Fuse Block................8W-40-2, 3, 4, 12, 13
G101..............................8W-40-5
G204............................8W-40-2, 9
G301.............................8W-40-11
Headlamp Beam Select...............8W-40-12
Headlamp Leveling Switch............8W-40-10
Headlamp Switch...............8W-40-2, 12, 14Component Page
High Beam Indicator.................8W-40-11
Ignition Switch....................8W-40-7, 8
Indicator Drivers....................8W-40-11
Instrument Cluster.......8W-40-2, 3, 4, 6, 7, 8, 9,
10, 11, 12, 13, 14
Instrument Panel Drivers......8W-40-6, 7, 8, 9, 14
Left Front Fog Lamp................8W-40-13
Left Front Turn Signal Lamp...........8W-40-3
Left Park/Turn Signal Lamp..........8W-40-3, 4
Left Rear Door Ajar Switch...........8W-40-7, 8
Map/Reading Lamps..................8W-40-9
Multi-Function Switch..........8W-40-2, 3, 4, 9,
11, 12, 13, 14
Park Brake Switch..................8W-40-11
Passenger Door Ajar Switch..........8W-40-7, 8
Power Distribution Center.......8W-40-2, 3, 4, 14
Powertrain Control Module............8W-40-5
PRNDL Lamp......................8W-40-10
Radio.............................8W-40-10
Rear Window Defogger Switch.........8W-40-10
Remote Keyless Entry Module........8W-40-6, 8
Right Front Fog Lamp...............8W-40-13
Right Front Turn Signal Lamp..........8W-40-3
Right Park/Turn Signal Lamp.........8W-40-3, 4
Right Rear Door Ajar Switch..........8W-40-7, 8
Seat Belt Indicator..................8W-40-11
Seat Belt Switch....................8W-40-11
Sentry Key Immobilizer Module.........8W-40-6
Traction Control Switch..............8W-40-10
Vehicle Speed Sensor.................8W-40-5
PL8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1

INSTRUMENT
CLUSTER
A (8W-40-5)
21
193
AIRBAG
CONTROL
MODULE
FUEL
PUMP
MODULE
MODULE ENTRY
KEYLESS
REMOTEFROM
C104
A12C30512G4
18
DB
G4
18
DB
D25
18
VT/YLD25
20
VT/YLD25
22
VT/YL
D25
22
VT/YL
S217
FUEL
LEVEL
SENSOR
SIGNALPCI
BUS
BUSPCI
BUSPCI
VT/YL22 D25
2
MODULE IMMOBILIZER
KEY
SENTRY
2 7
INSTRUMENT
PANEL
DRIVERS
SPEEDOMETER FUEL
GAUGE
INDICATOR PRESSURE
OIL
LOW BRAKE
WARNING
INDICATOR TRACTION
OFF
INDICATOR AIRBAG
WARNING
INDICATORLOW
FUEL
INDICATOR ABS
INDICATOR CHECK
ENGINE
INDICATOR
GAUGE TEMPERATURE
COOLANT
ENGINE TACHOMETER
ODOMETER/TRIP
INDICATOR AJAR
DOOR TRACTION
CONTROL
OFF
INDICATOR INDICATOR
ENGAGED
CRUISE(8W-43-2)
(8W-30-10)
(8W-39-10)
(8W-39-11) (8W-39-3)
(8W-30-4)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTERPL
008W-10PLI04006

ENGINE
TABLE OF CONTENTS
page page
STANDARD SERVICE PROCEDURES........... 1
ENGINE DIAGNOSIS........................ 82.0L SOHC ENGINE....................... 15
STANDARD SERVICE PROCEDURES
TABLE OF CONTENTS
page page
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS........1
ENGINE GASKET SURFACE PREPARATION.....2
CRANKSHAFT DAMPER BOLT ACCESS PLUG . . . 2
ENGINE CORE PLUGS.....................2
ENGINE PERFORMANCE...................3HONING CYLINDER BORES.................3
MEASURING WITH PLASTIGAGE.............4
REPAIR OF DAMAGED OR WORN THREADS....5
HYDROSTATIC LOCKED ENGINE.............5
CHECKING ENGINE OIL LEVEL..............6
ENGINE OIL SERVICE......................7
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANT
MopartBed Plate Sealant is a unique (green-in-
color) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components. The material
cures slowly in the absence of air when torqued
between two metallic surfaces, and will rapidly cure
when heat is applied.
PLENGINE 9 - 1

any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.).
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
CHECKING ENGINE OIL LEVEL
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick (Fig. 7) and observe oil
level. Add oil only when the level is at or below the
ADD mark (Fig. 8).
Fig. 7 Dipstick and Engine Oil Fill Locations
1 ± ENGINE OIL FILL
2 ± ENGINE COOLANT RECOVERY CONTAINER3 ± ENGINE OIL DIPSTICK
4 ± COOLING SYSTEM PRESSURE CAP
Fig. 8 Oil Level
1 ± ENGINE OIL LEVEL DIPSTICK
9 - 6 ENGINEPL
GENERAL INFORMATION (Continued)

should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
ENGINE OIL LEAK INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
PLENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)

FUEL INJECTION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INJECTION SYSTEM......................22
MODES OF OPERATION...................22
SYSTEM DIAGNOSIS......................24
POWER DISTRIBUTION CENTER............24
POWERTRAIN CONTROL MODULE...........24
PCM GROUND...........................26
5 VOLT SUPPLYÐPCM OUTPUT.............26
8-VOLT SUPPLYÐPCM OUTPUT.............26
FUEL CORRECTION or ADAPTIVE MEMORIES . . 26
PROGRAMMABLE COMMUNICATIONS
INTERFACE (PCI) BUS...................27
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT..............27
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT...........................27
BATTERY VOLTAGEÐPCM INPUT............28
BRAKE SWITCHÐPCM INPUT...............28
CAMSHAFT POSITION SENSORÐPCM INPUT . . 28
CLUTCH INTERLOCK/UPSTOP SWITCH.......29
CRANKSHAFT POSITION SENSORÐPCM
INPUT................................30
ENGINE COOLANT TEMPERATURE
SENSORÐPCM INPUT...................30
FUEL LEVEL SENSORÐPCM INPUT..........31
HEATED OXYGEN SENSOR (O2 SENSOR)Ð
PCM INPUT...........................32
IGNITION CIRCUIT SENSEÐPCM INPUT......34
INLET AIR TEMPERATURE SENSORÐPCM
INPUT................................34
KNOCK SENSORÐPCM INPUT..............34
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT...................35
POWER STEERING PRESSURE SWITCHÐ
PCM INPUT...........................35
SENSOR RETURNÐPCM INPUT.............35
SPEED CONTROLÐPCM INPUT.............36
SCI RECEIVEÐPCM INPUT.................36
PARK/NEUTRAL POSITION SWITCHÐPCM
INPUT................................36
THROTTLE POSITION SENSORÐPCM INPUT . . 36VEHICLE SPEED SIGNAL (VSS)ÐPCM INPUT . . 37
AIR CONDITIONING CLUTCH RELAYÐPCM
OUTPUT..............................38
AUTOMATIC SHUTDOWN RELAYÐPCM
OUTPUT..............................38
CHARGING SYSTEM INDICATOR LAMPÐPCM
OUTPUT..............................38
FUEL PUMP RELAYÐPCM OUTPUT..........38
PROPORTIONAL PURGE SOLENOIDÐPCM
OUTPUT..............................39
GENERATOR FIELDÐPCM OUTPUT..........39
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . . 39
DATA LINK CONNECTOR...................40
FUEL INJECTORSÐPCM OUTPUT...........40
IGNITION COILÐPCM OUTPUT..............40
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT...................41
SPEED CONTROLÐPCM INPUT.............41
SCI RECEIVEÐPCM OUTPUT...............41
TACHOMETERÐPCM OUTPUT..............42
TORQUE CONVERTOR CLUTCH SOLENOIDÐ
PCM OUTPUT..........................42
REMOVAL AND INSTALLATION
THROTTLE BODY........................42
THROTTLE POSITION SENSOR.............43
IDLE AIR CONTROL MOTOR................43
MAP SENSOR...........................44
POWERTRAIN CONTROL MODULE (PCM).....44
UPSTREAM HEATED OXYGEN SENSOR......45
DOWNSTREAM HEATED OXYGEN SENSOR
1/2 ..................................46
AIR CLEANER BOX.......................46
AIR CLEANER ELEMENT...................47
ENGINE COOLANT TEMPERATURE SENSOR . . . 47
VEHICLE SPEED SENSOR.................47
KNOCK SENSOR.........................48
SPECIFICATIONS
VECI LABEL.............................49
TORQUE...............................49
SPECIAL TOOLS
FUEL..................................49
PLFUEL SYSTEM 14 - 21

²Air Conditioning Controls
²Battery Voltage
²Inlet Air/Battery Temperature Sensor
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Engine Coolant Temperature Sensor
²Fuel Level Sensor
²Ignition Switch
²Inlet Air/Intake Air Temperature Sensor
²Knock Sensor
²Manifold Absolute Pressure (MAP) Sensor
²Oxygen Sensors
²Power Steering Pressure Switch²SCI Receive
²Speed Control Switches
²Throttle Position Sensor
²Transmission Park/Neutral Switch (automatic
transmission)
²Vehicle Speed Sensor
PCM Outputs:
²Air Conditioning WOT Relay
²Auto Shutdown (ASD) Relay
²Charging Indicator Lamp
²Data Link Connector
²Proportional Purge Solenoid
²EGR Solenoid
²Fuel Injectors
²Fuel Pump Relay
²Generator Field
²Idle Air Control Motor
²Ignition Coils
²Malfunction Indicator (Check Engine) Lamp
²Radiator Fan Relay
²Speed Control Solenoids
²Tachometer
²Torque Convertor Clutch Solenoid
Based on inputs it receives, the PCM adjusts fuel
injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and EVAP canister purge
operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM
changes generator charge rate by adjusting the gen-
erator field. The PCM also performs diagnostics.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery voltage
²Coolant temperature
²Inlet Air/Intake air temperature
²Exhaust gas content (oxygen sensor)
²Engine speed (crankshaft position sensor)
²Manifold absolute pressure
²Throttle position
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Coolant temperature
²Inlet Air/Intake air temperature
²Engine speed (crankshaft position sensor)
²Knock sensor
²Manifold absolute pressure
²Throttle position
²Transmission gear selection (park/neutral
switch)
The PCM also adjusts engine idle speed through
the idle air control motor based on the following
inputs.
²Air conditioning sense
²Battery voltage
²Battery temperature
²Brake switch
Fig. 1 Power Distribution Center (PDC)
Fig. 2 Powertrain Control Module (PCM)
1 ± PCM
PLFUEL SYSTEM 14 - 25
DESCRIPTION AND OPERATION (Continued)