Dodge Neon / Neon SRT-4. Manual — part 66
REMOVAL
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(2) Detach power cord plug from heater (Fig. 8).
(3) Loosen screw in center of heater. Remove
heater assembly (Fig. 8).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tioned upward (Fig. 8).
(3) With
heater
seated,
tighten
center
screw
securely to assure a positive seal.
(4) Connect power cord to block heater (Fig. 8).
(5) Fill the cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature (ECT) sensor
threads into the rear of the cylinder head, next to the
camshaft position sensor (Fig. 9). New sensors have
sealant applied to the threads.
The ECT Sensor is a Negative Thermal Coefficient
(NTC) Sensor. The resistance of the ECT Sensor
changes as coolant temperature changes. This results
in different input voltages to the PCM. The PCM also
uses the ECT Sensor input to operate the radiator
cooling fan(s), and send a message over the PCI bus
to the instrument cluster for temperature gauge
operation.
OPERATION
The ECT sensor provides an input to the PCM. As
temperature
increases,
resistance
of
the
sensor
decreases. As coolant temperature varies, the ECT
sensor resistance changes resulting in a different
voltage value at the PCM ECT sensor signal circuit.
The ECT sensor provides input for various PCM
operations. The PCM uses the input to control air-
fuel mixture, timing, and radiator fan on/off times.
The PCM uses ECT sensor input to send messages
over the PCI bus for temperature gauge operation.
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(2) Disconnect coolant sensor electrical connector
(Fig. 9).
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 18
N·m (165 in. lbs.) torque.
(2) Attach electrical connector to sensor (Fig. 9).
(3) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
Fig. 8 Engine Block Heater
1 - CORE PLUG
2 - BLOCK HEATER
3 - POWER CORD
Fig. 9 Engine Coolant Temperature Sensor—SOHC
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CAMSHAFT POSITION SENSOR
7 - 22
ENGINE - 2.0L SOHC
PL/SRT-4
ENGINE BLOCK HEATER (Continued)
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The engine thermostat is located on the left front
side (radiator side) of the cylinder head in the ther-
mostat housing/engine outlet connector (Fig. 10). The
thermostat has an air bleed (vent) located in the
flange and a O-ring for sealing incorporate on it. A
relief in the thermostat housing/outlet connector is
provided for the O-ring.
OPERATION
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 93°C (192 to 199°F). Also,
the thermostat will automatically reach wide open, to
accommodate unrestricted flow to the radiator as
temperature of the coolant rises in hot weather to
around 104°C (220°F). Above this temperature the
coolant temperature is controlled by the radiator, fan,
and ambient temperature—not 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.
DIAGNOSIS AND TESTING - ENGINE
THERMOSTAT TESTING
The thermostat that opens too soon type failure
mode is included in the on-board diagnosis. The
check engine light will not be lit by an open too soon
condition. If it has failed open, a diagnostic trouble
code (DTC) will be set. Do not change a thermostat
for lack of heater performance or temperature gauge
position, unless a DTC is present. (Refer to Appropri-
ate
Diagnostic
Information)
For
other
probable
causes, (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Thermostat failing shut is the
normal long term mode of failure, and normally, only
on high mileage vehicles. The temperature gauge will
indicate this (Refer to 7 - COOLING/ENGINE -
DIAGNOSIS AND TESTING).
REMOVAL
(1) Drain cooling system to the thermostat level or
below (Refer to 7 - COOLING/ENGINE - STANDARD
PROCEDURE).
(2) Remove coolant recovery/reserve system hose
and radiator upper hose.
(3) Remove
thermostat/engine
outlet
connector
bolts (Fig. 10).
(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 the radiator upper hose.
(5) Connect the coolant recovery/reserve system
hose.
(6) Fill the cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
Fig. 10 Thermostat/Engine Outlet Connector
1 - PRESSURE CAP
2 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
3 - THERMOSTAT
4 - O-RING
5 - VENT FACING UP
PL/SRT-4
ENGINE - 2.0L SOHC
7 - 23
HEATER SUPPLY/RETURN
TUBES
REMOVAL
NOTE: It is not necessary to remove the intake
manifold to replace heater supply/return tubes.
(1) Disconnect negative battery cable. Disconnect
positive battery cable. Remove battery.
(2) Raise vehicle on hoist.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(4) Remove hose clamp from heater return tube
located near starter. Disconnect hose from tube (Fig.
11).
(5) Lower vehicle
(6) Remove air cleaner housing and throttle body
to intake manifold hose.
(7) Disconnect PCV vacuum hose at intake mani-
fold.
(8) Remove hose clamp from heater supply tube
located near thermostat housing. Disconnect hose
from tube.
(9) Remove two heater hose clamps and disconnect
heater hoses near battery.
(10) Unclip
wiring
harness
from
heater
tube
assembly.
(11) Remove transmission dipstick tube and place
an appropriate plug into hole to prevent coolant from
entering transmission.
(12) Remove
fasteners
attaching
heater
tube
assembly to cylinder head and engine block (Fig. 11).
(13) Remove heater tube assembly.
NOTE: After heater tube assembly is removed, the
short hoses connecting the tubes to the thermostat
housing and water pump inlet tube can be replaced
at this time.
INSTALLATION
(1) Inspect all hoses that connect to heater tubes.
Replace if necessary.
(2) Position heater tube assembly near it’s mount-
ing location.
(3) Connect hoses at water pump inlet tube and
thermostat housing. Ensure clamps are positioned
properly to seal hoses and avoid contact with engine
components.
(4) Install fasteners attaching heater tube assem-
bly to cylinder head and engine block (Fig. 11).
NOTE: Before installing transmission dipstick tube
clean any residual coolant from around the area
where plug was placed.
(5) Remove plug from transmission dipstick tube
mounting hole. Install transmission dipstick tube.
(6) Reattach wiring harness to heater tube assem-
bly.
(7) Connect two heater hoses to heater tubes near
battery. Ensure clamps are positioned properly to
seal hoses and avoid contact with engine components.
(8) Connect PCV vacuum hose to intake manifold.
(9) Install air cleaner housing and throttle body to
intake manifold hose.
(10) Raise vehicle on hoist.
(11) Close radiator draincock.
(12) Lower vehicle
(13) Install battery. Connect positive battery cable.
Connect negative battery cable.
(14) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS
The cooling system utilizes spring type hose
clamps. If a spring type clamp replacement is neces-
sary, replace with the original Mopar
t equipment
spring type clamp.
Fig. 11 Heater Supply/Return Tube Assembly
NOTE: INTAKE MANIFOLD REMOVED FOR GRAPHIC
PURPOSES
1 - FASTENERS
2 - HEATER SUPPLY/RETURN TUBE ASSEMBLY
3 - CLAMPS
4 - HOSE
5 - WATER PUMP INLET TUBE
7 - 24
ENGINE - 2.0L SOHC
PL/SRT-4
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 12).
OPERATION
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
(Special Tool 8495) designed to compress the hose
clamp. For Special Tool Identification, (Refer to 7 -
COOLING - SPECIAL TOOLS).
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 the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(3) Remove the radiator upper hose from the radi-
ator.
(4) Disconnect the radiator fan motor electrical
connector.
(5) Remove the radiator fan assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL)
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses and clamps must be replaced.
(6) Disconnect and cap automatic transmission
hoses (if equipped) (Fig. 13).
(7) Remove the radiator lower hose.
(8) Remove radiator upper isolator bracket mount-
ing screws (Fig. 14). Disconnect the engine block
heater wire (if equipped).
(9) Remove the A/C condenser attaching screws
located at the front of the radiator (if equipped) (Fig.
15), then lean condenser forward.
NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.
Fig. 12 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
Fig. 13 Transmission Cooler Hoses to Cooler
1 - COOLER FITTING
2 - HOSE - COOLER SUPPLY
3 - HOSE - COOLER RETURN
4 - COOLER FITTING
Fig. 14 Radiator Mounting
1 - RADIATOR UPPER HOSE
2 - RADIATOR UPPER MOUNTS
PL/SRT-4
ENGINE - 2.0L SOHC
7 - 25
HOSE CLAMPS (Continued)
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