Dodge Neon / Neon SRT-4. Manual — part 68

RADIATOR FAN OPERATION CHART

Radiator Fan Control

A/C Off

Vehicle

Speed < 36

mph

Vehicle

Speed

≥

44

mph

Fan On:

97° C (210°

F)

104° C (219°

F)

Fan Off:

94° C (201°

F)

97° C (210° F)

WOT* <

113° C

(235° F)

A/C On

Fan On—regardless of coolant
temperature or vehicle speed.

*WOT = Wide Open Throttle

DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR

(Refer to Appropriate Diagnostic Information)

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 cooling system below the upper radiator

hose level (Refer to 7 - COOLING/ENGINE - STAN-
DARD PROCEDURE).

(3) Remove upper hose from radiator (Fig. 24).

(4) Remove fasteners that attach air cleaner hous-

ing to vehicle. Reposition air cleaner housing.

(5) Raise vehicle on hoist.
(6) Disconnect and remove the powertrain control

module (PCM) with bracket (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/POWER-
TRAIN CONTROL MODULE - REMOVAL).

(7) Disconnect radiator fan electrical connector

(Fig. 25).

(8) Lower vehicle.
(9) Remove radiator upper support mounts (Fig.

24).

(10) Remove air conditioning line support bracket

screw (Fig. 26).

(11) Remove radiator fan assembly screws from

radiator (Fig. 24).

(12) Carefully lift radiator fan assembly up and

out of lower shroud attachment clips.

(13) For radiator fan assembly sub-component

removal procedures (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - DISASSEMBLY).

Fig. 24 Radiator and Fan

1 - RADIATOR FAN ATTACHING SCREWS
2 - RADIATOR HOSE - UPPER
3 - RADIATOR SUPPORTS - UPPER

Fig. 25 Radiator Fan Motor Connector

1 - RADIATOR FAN ELECTRICAL CONNECTOR
2 - RADIATOR HOSE - LOWER

Fig. 26 A/C Line Support

1 - A/C LINE
2 - SCREW

7 - 30

ENGINE - 2.0L SOHC

PL/SRT-4

RADIATOR FAN (Continued)

DISASSEMBLY

The radiator fan assembly consist of the following

three components: fan, fan motor, and shroud.

FAN

There are no repairs to be made to the fan. If the

fan is warped, cracked, or otherwise damaged, it
must be replaced with only the recommended part
for adequate strength, performance and safety.

(1) Remove radiator fan assembly (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(2) Remove fan hub retaining nut (Fig. 27) or (Fig.

28).

(3) Remove fan from motor shaft.

FAN MOTOR

(1) Remove radiator fan assembly. (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - REMOVAL)

(2) Remove fan from motor shaft.
(3) Remove screw attaching the in-rush current

suppressor (Fig. 29).

(4) Remove screws attaching motor to shroud (Fig.

29).

(5) Remove the fan motor.

SHROUD

(1) Remove radiator fan assembly (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(2) Remove the FAN.
(3) Remove the FAN MOTOR.

ASSEMBLY

FAN

There are no repairs to be made to the fan. If the

fan is warped, cracked, or otherwise damaged, it
must be replaced with only the recommended part
for adequate strength, performance and safety.

(1) Install fan on motor shaft.
(2) Install fan retaining nut and tighten to 6.2

N·m (55 in. lbs.) (Fig. 27) or (Fig. 28).

(3) Install radiator fan assembly. (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION)

FAN MOTOR

(1) Install the fan motor on shroud and tighten

screws to 3.8 N·m (34 in. lbs.) (Fig. 29).

(2) Install screw attaching the in-rush current sup-

pressor and tighten to 2.6 N·m (23 in. lbs.) (Fig. 29).

(3) Install the fan on motor shaft.

Fig. 27 Single Fan Disassembly/Assembly

1 - FAN
2 - NUT
3 - SHROUD ASSEMBLY

Fig. 28 Dual Fan Disassembly/Assembly

1 - NUT
2 - SHROUD
3 - FAN

Fig. 29 Fan Motor - Removal and Installation

1 - FAN MOTOR SCREWS
2 - IN RUSH CURRENT SUPPRESSOR SCREW

PL/SRT-4

ENGINE - 2.0L SOHC

7 - 31

RADIATOR FAN (Continued)

(4) Install the radiator fan assembly (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).

SHROUD

(1) Install the FAN MOTOR.
(2) Install the FAN.
(3) Install the radiator fan assembly (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).

INSTALLATION

(1) Install radiator fan assembly by lowering into

position on radiator. Ensure the fan assembly lower
mounts (Fig. 21) or (Fig. 22) are engaged properly
into slots on lower radiator tank.

(2) Install the radiator fan assembly retaining

screws and tighten to 7.5 N·m (65 in. lbs.) (Fig. 24).

(3) Install radiator upper support mounts (Fig. 24)

and tighten bolts to 10 N·m (90 in. lbs.).

(4) Install air conditioning line support bracket

screw (Fig. 26).

(5) Raise vehicle on hoist.
(6) Connect radiator fan electrical connector (Fig.

25).

(7) Install powertrain control module (PCM) (Refer

to

8

-

ELECTRICAL/ELECTRONIC

CONTROL

MODULES/POWERTRAIN CONTROL MODULE -
INSTALLATION).

(8) Lower vehicle.
(9) Install air cleaner housing fasteners.
(10) Install radiator upper hose to radiator (Fig.

24). Align hose and position clamp to ensure proper
clearance with engine or hood.

(11) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(12) Connect negative battery cable.

THERMOSTAT HOUSING

REMOVAL

(Refer to 7 - COOLING/ENGINE/ENGINE COOL-

ANT THERMOSTAT - REMOVAL)

INSTALLATION

(Refer to 7 - COOLING/ENGINE/ENGINE COOL-

ANT THERMOSTAT - INSTALLATION)

WATER PUMP

DESCRIPTION

The water pump has a diecast aluminum body and

housing with a stamped steel impeller. The water
pump bolts directly to the cylinder block and is
driven by the timing belt (Fig. 30). Cylinder block to
water pump sealing is provided by a rubber O-ring.

NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.

DIAGNOSIS AND TESTING - WATER PUMP
DIAGNOSIS

A quick flow test to determine water pump opera-

tion is check for proper heater operation. A defective
pump will not circulate heated coolant through the
heater hoses.

An additional flow test can by performed by the

following the procedures below:

WARNING: DO NOT remove radiator cap if the cool-
ing system is hot or under pressure.

(1) Remove cooling system pressure cap.
(2) Remove a small amount of coolant from the

system.

(3) Start the engine and warm up until thermostat

opens.

(4) With the thermostat open and coolant level low,

visually inspect for coolant flow. If flow is present,
the water pump is pumping coolant through the sys-
tem.

REMOVAL

(1) Raise vehicle on a hoist. Remove right inner

splash shield.

(2) Remove accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

REMOVAL).

(3) Drain the cooling system (Refer to 7 - COOL-

ING/ENGINE - STANDARD PROCEDURE).

(4) Remove power steering pump attaching bolts

and set pump and assembly aside. Do Not discon-
nect power steering lines.

(5) Remove upper and lower torque isolator struts

(Refer

to

9

-

ENGINE/ENGINE

MOUNTING/

TORQUE STRUT - REMOVAL).

(6) Support the engine from bottom and remove

right engine mount attaching bolt.

(7) Remove right engine mount bracket (Refer to 9

- ENGINE/ENGINE MOUNTING/ENGINE MOUNT
BRACKET - REMOVAL).

7 - 32

ENGINE - 2.0L SOHC

PL/SRT-4

RADIATOR FAN (Continued)

(8) Remove the timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL)

(9) Remove the timing belt tensioner (Refer to 9 -

ENGINE/VALVE

TIMING/TIMING

BELT

TEN-

SIONER & PULLEY - REMOVAL).

(10) Remove camshaft sprocket and rear timing

belt cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).

(11) Remove screws attaching water pump to

engine and remove pump (Fig. 30).

INSPECTION

Replace water pump body assembly if it has any of

these defects:

(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by

wet coolant traces on the pump body.

(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the

engine block.

(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.

INSTALLATION

(1) Apply Mopar

t Dielectric Grease to O-ring

before installation.

(2) Install new O-ring gasket in water pump body

O-ring groove (Fig. 31).

CAUTION: Ensure O-ring gasket is properly seated
in water pump groove before tightening screws. An
improperly located O-ring may cause damage to the
O-ring, resulting in a coolant leak.

(3) Assemble pump body to block and tighten

screws to 12 N·m (105 in. lbs.). Pressurize cooling
system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.

(4) Rotate pump by hand to check for freedom of

movement.

(5) Install timing belt rear cover and camshaft

sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT COVER(S) - INSTALLATION).

(6) Install timing belt tensioner (Refer to 9 -

ENGINE/VALVE

TIMING/TIMING

BELT

TEN-

SIONER & PULLEY - INSTALLATION).

(7) Install the timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).

(8) Install the engine right mount bracket (Refer

to

9

-

ENGINE/ENGINE

MOUNTING/ENGINE

MOUNT BRACKET - INSTALLATION).

(9) Install the upper and lower torque isolator

struts (Refer to 9 - ENGINE/ENGINE MOUNTING/
TORQUE STRUT - INSTALLATION).

(10) Fill the cooling system (Refer to 7 - COOL-

ING/ENGINE - STANDARD PROCEDURE).

(11) Install the accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

INSTALLATION).

Fig. 30 Water Pump

1 - CYLINDER BLOCK
2 - PUMP BODY

Fig. 31 Water Pump

1 - IMPELLER
2 - PUMP BODY
3 - O-RING

PL/SRT-4

ENGINE - 2.0L SOHC

7 - 33

WATER PUMP (Continued)