2000 DODGE NEON coolant

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................8W-80-4
A/C Cycling Switch...................8W-80-4
A/C Heater Blower Motor..............8W-80-4
A/C Heater Control...................8W-80-4
A/C High Pressure Switch.............8W-80-4
A/C Low Pressure Switch..............8W-80-5
Airbag Control Module................8W-80-5
Back-Up Lamp Switch................8W-80-5
Blower Motor Resistor Block...........8W-80-6
Brake Lamp Switch..................8W-80-6
Brake Shift Interlock Solenoid..........8W-80-6
Brake Warning Indicator Switch........8W-80-6
C101..............................8W-80-7
C102..............................8W-80-7
C103..............................8W-80-8
C104..............................8W-80-9
C105.............................8W-80-10
C106.............................8W-80-10
C107.............................8W-80-10
C108.............................8W-80-10
C109.............................8W-80-11
C110 .............................8W-80-11
C111 .............................8W-80-11
C201.............................8W-80-12
C202.............................8W-80-13
C203.............................8W-80-13
C204.............................8W-80-13
C205.............................8W-80-14
C301.............................8W-80-15
C302.............................8W-80-15Component Page
C303.............................8W-80-15
C304.............................8W-80-15
C305..........................8W-80-16, 17
C306.............................8W-80-17
Camshaft Position Sensor.............8W-80-18
Cargo Lamp.......................8W-80-18
Center High Mounted Stop Lamp.......8W-80-18
Center Stack Lamp..................8W-80-18
Cigar Lighter/Power Outlet............8W-80-18
Clockspring........................8W-80-19
Clutch Interlock Switch..............8W-80-19
Controller Anti-Lock Brake............8W-80-19
Crankshaft Position Sensor............8W-80-20
Data Link Connector.................8W-80-20
Decklid Solenoid....................8W-80-20
Dome Lamp.......................8W-80-20
Dome Lamp/Intrusion Sensor..........8W-80-21
Driver Airbag......................8W-80-21
Driver Cylinder Lock Switch...........8W-80-21
Driver Door Lock Motor..............8W-80-21
Driver Door Lock Switch..............8W-80-21
Driver Power Mirror.................8W-80-22
Driver Power Window Motor...........8W-80-22
Driver Power Window Switch..........8W-80-23
Engine Coolant Temperature Sensor.....8W-80-23
Engine Oil Pressure Switch...........8W-80-24
Fuel Injector No. 1..................8W-80-24
Fuel Injector No. 2..................8W-80-24
Fuel Injector No. 3..................8W-80-24
Fuel Injector No. 4..................8W-80-24
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 K2 20TN/BK
ENGINE COOLANT
TEMPERATURE
SENSOR
BLACK
SWITCH - C2WINDOW DRIVER POWERQ16 14BR/WT 8 6
Q16 14BR/WT 5
Q26 14VT/WT 5
F21 14TN 4
Z8 14BK/VT 3
Z8 14BK/VT 2
1
5 81 4
GRAYCAV CIRCUIT FUNCTION
-
GROUND
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN)
MASTER WINDOW SWITCH RIGHT FRONT DOWN
MASTER WINDOW SWITCH RIGHT FRONT UP
FUSED IGNITION SWITCH OUTPUT (RUN) -
GROUND
7
Z14 18BK/YL
8 Q26 14VT/WTF20 20WT
RHD LHD
2 1
MASTER WINDOW SWITCH RIGHT FRONT UP
MASTER WINDOW SWITCH RIGHT FRONT DOWN
GROUND Z14 18BK/YL F20 20WT
Q21 14WT/LB 8
DRIVER WINDOW DRIVER DOWN Z14 18BK/YL
7
GROUND -
DRIVER WINDOW DRIVER UP FUSED IGNITION SWITCH OUTPUT (RUN) DRIVER WINDOW DRIVER UP DRIVER WINDOW DRIVER DOWN FUSED IGNITION SWITCH OUTPUT (RUN) GROUND GROUND- FUNCTION CIRCUIT CAV
BLACK
41
85
1
2 Z8 14BK/VT
3 Z8 14BK/VT
4 F21 14TN
5 Q21 14WT/LB
5 Q11 14LB
6
8 Q11 14LBDRIVER POWER
WINDOW
SWITCH - C1
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23
PLI08023008W-10

HEATED OXYGEN SENSOR RELAY CONTROL FUEL INJECTOR NO. 2 DRIVER FUEL INJECTOR NO. 4 DRIVER
37MAP SENSOR SIGNAL 20DG/RD K1 36MODULE - C1CONTROL POWERTRAIN
25
26 K2 20TN/BK
27
28 - -
29 - -
30 K41 20BK/DG OXYGEN SENSOR 1/1 SIGNAL
31
32 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
34
35 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
38 C20 18BR/OR A/C SWITCH SENSE
39 - -
40
BLACK
10 120 1130 2140 31
KNOCK SENSOR SIGNAL 20DB/LG K42 24CLUTCH SWITCH K119 18LG/BK 23- - 22- - 21FUSED IGNITION SWITCH OUTPUT (ST-RUN) 18DB/WT F12
20- - 19K79 18OR/RD 1818TN K12 1718LB/BR K14 16- - 15- - 14FUEL INJECTOR NO. 1 DRIVER 18WT/DB K11 13 12 11GROUND 18BK/TN Z12 10- - 9GENERATOR FIELD DRIVER (+) K20 18DG 8FUEL INJECTOR NO. 3 DRIVER 18YL/WT K13 7AUTOMATIC SHUT DOWN RELAY OUTPUT 18DG/OR A142 6SPEED CONTROL POWER SUPPLY 20YL/RD V32 5 4IGNITION COIL NO. 2 DRIVER 18DB/TN K17 3 2- - 1FUNCTION CIRCUIT CAV
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL --
--
K19 18BK/GY IGNITION COIL NO. 1 DRIVER
ENGINE OIL PRESSURE SWITCH SENSE G6 20GY
K127 18BK/OR
OXYGEN SENSOR GROUND
20TN K90 ENGINE STARTER MOTOR RELAY CONTROL
--
--
SPEED CONTROL- - --
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37
PLI08037008W-10

Connector
Name/NumberColor Location Fig.
C204 RD Left Side of
Instrument
Panel6, 8, 9
C205 GY Left Side of
Instrument
Panel6, 8,
14
C301 RD Right C-Pillar 11
C302 BK Inner Left
Rear Quarter
Panel11
C303 BL/BK Left B-Pillar at
Rear Door10, 16
C304 BL/BK Right B-Pillar
at Rear Door12, 16
C305 NAT Left Side of
Instrument
Panel6, 8,
10
C306 BK Front Center
of Headliner9
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf11
Center High
Mounted Stop
LampBK Rear of Lamp 17
Center Stack
LampBK Center of
Instrument
Panel7
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel7
Clockspring GN Rear of
Steering
Wheel6
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal2
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower2
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK At Left Kick
Panel Area2Connector
Name/NumberColor Location Fig.
Decklid
SolenoidBK On Decklid 17
Dome Lamp
(Except
Built-Up-
Export)BK At Lamp N/S
Dome
Lamp/Intrusion
Sensor
(Built-Up-
Export)NAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door14
Driver Door
Lock MotorBK At Drivers
Door14
Driver Door
Lock SwitchBK At Drivers
Door14
Driver Power
MirrorGY At Drivers
Door14
Driver Power
Window MotorBK At Drivers
Door14
Driver Power
Window
Switch - C1BK At Drivers
Door14
Driver Power
Window
Switch - C2GY At Drivers
Door14
Engine
Coolant
Temperature
SensorBK Right Front of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine5
Fuel Injector
NO.1BK At Injector 4
Fuel Injector
NO. 2BK At Injector 4
Fuel Injector
NO. 3BK At injector 4
Fuel Injector
NO. 4BK At Injector 4
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
C303 BL/BK Left B-Pillar at
Left Rear
Door28, 35
C304 BL/BK Right B-Pillar
at Right Rear
Door29, 31,
35
C305 NAT Right Side of
Instrument
Panel25, 26,
29
C306 BK Front Center
of Headliner27
Camshaft
Position
SensorBK Rear of
EngineN/S
Cargo Lamp BK Under Parcel
Shelf30
Center High
Mounted Stop
LampBK Rear of Lamp 36
Center Stack
LampBK Center of
Instrument
Panel24
Cigar
Lighter/Power
OutletRD Center of
Instrument
Panel24
Clockspring GN Rear of
Steering
Wheel25
Clutch
Interlock
Switch (MTX)BK Top of Clutch
Pedal23
Controller
Anti-Lock
BrakeBK Near Left
Strut Tower19
Crankshaft
Position
SensorBK Right Front of
EngineN/S
Data Link
ConnectorBK Right Front
Kick Panel23
Decklid
SolenoidBK On Decklid 36
Dome
Lamp/Intrusion
SensorNAT At Lamp N/S
Driver Cylinder
Lock SwitchBK At Drivers
Door34
Driver Door
Lock MotorBK At Drivers
Door34Connector
Name/NumberColor Location Fig.
Driver Door
Lock SwitchBK At Drivers
Door34
Driver Power
MirrorBL At Drivers
Door34
Driver Power
Window MotorBK At Drivers
Door34
Driver Power
Window
Switch - C1BK At Drivers
Door34
Driver Power
Window
Switch - C2GY At Drivers
Door34
Engine
Coolant
Temperature
SensorBK Right Side of
EngineN/S
Engine Oil
Pressure
SwitchGN Right Rear of
Engine22
Fuel Injector
NO. 1BK At Injector 21
Fuel Injector
NO. 2BK At Injector 21
Fuel Injector
NO. 3BK At injector 21
Fuel Injector
NO. 4BK At Injector 21
Fuel Pump
ModuleLT GY At Fuel Tank N/S
G101 Left Front of
Engine
CompartmentN/S
G102 Left Front of
Engine
CompartmentN/S
G103 Right Front of
Engine
Compartment20
G104 Near Engine
Starter MotorN/S
G105 Near Negative
Battery
TerminalN/S
G201 Lower Center
of Instrument
Panel24, 26
8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

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

MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4 oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 1)NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 1)
²Drill motor with 3M RolocyBristle Disc (white
or yellow) (Fig. 1)
CAUTION: Excessive pressure or high RPM can
damage the sealing surfaces. The mild (white, 120
grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
on cast iron surfaces with care.
CRANKSHAFT DAMPER BOLT ACCESS PLUG
An access plug is located in the right splash shield
(Fig. 2). Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 3). With the cup plug rotated, grasp firmly
with pliers or other suitable tool and remove plug
(Fig. 3).
Fig. 1 Proper Tool Usage For Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
9 - 2 ENGINEPL
GENERAL INFORMATION (Continued)

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)