2000 DODGE NEON fuel filter

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 3).
FLUID CHECK/FILL POINTS AND LUBRICATION
LOCATIONS
The fluid check/fill points and lubrication locations
are located in each applicable Sections.
LUBRICATION POINT LOCATIONS
Lubrication point locations are located in each
applicable Sections.
SPECIFICATIONS
FLUID CAPACITIES
Fuel Tank (approximate)....47.5 Liter (12.5 gal.)
Engine Oil ± With Filter....... 4.3Liter (4.5 qts.)
Engine Oil ± Without Filter.... 3.8Liter (4.0 qts.)
Cooling System ± Includes Heater & Coolant
Recovery Bottle*........... 6.2Liter (6.5 qts.)
Automatic Transaxle ± Estimated Service
Fill........................ 3.8L(4.0 qts.)
Automatic Transaxle ± 31 TH ± Overhaul Fill
Capacity with Torque Converter Empty . . . 8.4 L
(8.9. qts.)
Manual Transaxle ± NV T350........ 1.9to2.2L
(4.0 to 4.6 pts.)
*Capacities include 1 qt. for coolant reserve tank.
Fig. 2 NLGI Symbol
1 ± WHEEL BEARINGS
2 ± CHASSIS LUBRICATION
3 ± CHASSIS AND WHEEL BEARINGS
Fig. 3 International Symbols
0 - 2 LUBRICATION AND MAINTENANCEPL
DESCRIPTION AND OPERATION (Continued)

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES................3
SPECIFICATIONS
UNSCHEDULED INSPECTION................3SCHEDULE ± A...........................3
SCHEDULE ± B...........................4
DESCRIPTION AND OPERATION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Extensive idling
²More than 50% of the driving is at sustained
high speeds during hot weather, above 90É F (32É C)
SPECIFICATIONS
UNSCHEDULED INSPECTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
every other interval on Schedule ± B (6,000 miles -
10 000 km).
²Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed inbold
typeon the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable group.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km) or at 12 months
²Change the engine oil.
²Replace the engine oil filter.
²Adjust the drive belt tension.
22,500 Miles (36 000 km) or at 18 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the front brake pads and rear brake lin-
ings.
PLLUBRICATION AND MAINTENANCE 0 - 3

OPERATION
The Automatic Shutdown (ASD) relay supplies bat-
tery voltage to the fuel injectors, electronic ignition
coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC)
supplies voltage to the solenoid side and contact side
of the relay. The fuse also protects the power circuit
for the fuel pump relay and pump. The fuse is
located in the PDC. Refer to the Wiring Diagrams for
circuit information.
The PCM controls the ASD relay by switching the
ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the
ignition switch is in the Off position. When the igni-
tion switch is in On or Start, the PCM monitors the
crankshaft and camshaft position sensor signals to
determine engine speed and ignition timing (coil
dwell). If the PCM does not receive crankshaft and
camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the
ASD relay.
CRANKSHAFT POSITION SENSORÐPCM
INPUT
DESCRIPTION
The crankshaft position sensor mounts to the
engine block behind the generator, just above the oil
filter (Fig. 4).
The PCM uses the Crankshaft Position sensor to
calculate the following:
²Engine RPM²TDC number 1 and 4
²Ignition coil synchronization
²Injector synchronization
²Camshaft-to-crankshaft misalignment (Timing
belt skipped 1 tooth or more diagnostic trouble code).
OPERATION
The Crankshaft Position (CKP) sensor is a Hall-ef-
fect sensor. The second crankshaft counterweight has
two sets of four timing reference notches including a
60 degree signature notch (Fig. 5).
Fig. 5 Timing Reference Notches
1 ± MACHINED NOTCHES
2 ± CRANKSHAFT POSITION SENSOR
Fig. 4 Crankshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± OIL FILTER
3 ± GENERATOR
PLIGNITION SYSTEM 8D - 3
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)

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)

ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. Refer to
Group 8B, Starting.
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
Refer to Group 8D, Ignition System.
5. Incorrect spark plug gap. 5. Set gap. Refer to Group 8D,
Ignition System.
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s). 4. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Install new parts, as necessary.
9. Faulty coil(s). 9. Test and replace as necessary.
Refer to Group 8D, Ignition System.
PLENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE MISSES ON
ACCELERATION1. Dirty or incorrectly gapped spark
plugs.1. Clean spark plugs and set gap.
Refer to Group 8D, Ignition System.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty coil(s). 4. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
Refer to Group 8D, Ignition System.
2. Faulty coil(s). 2. Test and replace as necessary.
Refer to Group 8D, Ignition System.
3. Dirty fuel injector(s). Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
ENGINE DIAGNOSISÐMECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Low oil pressure. 3. Check and correct engine oil
level.
4. Dirt in tappets/lash adjusters. 4. Replace rocker arm/hydraulic
lash adjuster assembly.
5. Worn rocker arms. 5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters. 6. Install new rocker arm/hydraulic
lash adjuster assembly.
7. Worn valve guides. 7. Ream guides and install new
valves with oversize stems.
8. Excessive runout of valve seats
on valve faces.8. Grind valve seats and valves.
9. Missing adjuster pivot. 9. Replace rocker arm/hydraulic
lash adjuster assembly.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal
out-of-round.5. Replace crankshaft or grind
surface.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
9 - 12 ENGINEPL
DIAGNOSIS AND TESTING (Continued)