Dodge Neon / Neon SRT-4. Manual — part 67

(10) Radiator can now be lifted free from engine

compartment. Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.

CLEANING

Clean radiator fins are necessary for good heat

transfer. The radiator and air conditioning fins
should be cleaned when an accumulation of debris
has occurred. With the engine cold, apply cold water
and compressed air to the back (engine side) of the
radiator to flush the radiator and/or A/C condenser of
debris.

INSPECTION

Inspect the radiator tanks for cracks, broken or

missing fittings also inspect the joint where the
tanks seam up to the radiator core for signs of leak-
age and/or deteriorating seals.

Inspect radiator core for corroded, bent or missing

cooling fins. Inspect the core for bent or damaged
cooling tubes.

INSTALLATION

(1) Install radiator into position behind the radia-

tor support (yoke).

(2) Attach A/C condenser to radiator (if equipped)

(Fig. 15), with four mounting screws. Tighten screws
to 7.2 N·m (65 in. lbs.). Then seat the radiator
assembly lower rubber isolators into the mounting
holes provided in the lower crossmember.

(3) Install and tighten radiator isolator mounting

bracket screws to 10 N·m (90 in. lbs.) (Fig. 14). The
radiator should have clearance to move up, approxi-
mately 5–8 mm (0.20–0.31 in.) after assembled.

(4) Install the radiator lower hose. Align the hose

and position the clamp to prevent interference with
engine components.

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.

(5) Replace

automatic

transmission

hoses

and

clamps (if equipped) (Fig. 13).

(6) Install radiator fan assembly (Refer to 7 -

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

(7) Connect the radiator fan motor electrical con-

nector.

(8) Install the radiator upper hose. Align the hose

and position the clamp to prevent interference with
the engine or the hood.

(9) Connect negative cable to battery.
(10) Fill cooling system with coolant (Refer to 7 -

COOLING/ENGINE - STANDARD PROCEDURE).

(11) Operate engine until it reaches normal operat-

ing temperature. Check cooling system and auto-
matic transmission for correct fluid levels.

RADIATOR DRAINCOCK

REMOVAL

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

ING/ENGINE - STANDARD PROCEDURE).

(2) Turn the draincock stem counterclockwise to

unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 16) from
the radiator tank.

INSTALLATION

(1) Push the draincock assembly body into the

tank opening.

Fig. 15 A/C Condenser to Radiator Mounting Screws

1 - AIR CONDITIONING CONDENSER TO RADIATOR MOUNTING
SCREWS
2 - LOWER ISOLATOR MOUNTS

Fig. 16 Draincock

1 - DRAIN COCK BODY
2 - DRAIN COCK HOUSING

7 - 26

ENGINE - 2.0L SOHC

PL/SRT-4

RADIATOR (Continued)

(2) Tighten the draincock stem by turning clock-

wise to 2.0-2.7 N·m (18-25 in. lbs.).

(3) Fill the cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

COOLING SYSTEM PRESSURE
CAP

DESCRIPTION

The cooling system is equipped with a pressure cap

that releases built up pressure, maintaining a range
of 97-124 kPa (14-18 psi).

There is also a vent valve in the center of the cap.

This valve also opens when coolant is cooling and
contracting, allowing coolant to return to radiator
from coolant reserve/recovery system container by
vacuum through connecting hose. If valve is stuck
shut, the radiator hoses will be collapsed on
cool down. Clean the vent valve (Fig. 17) to
ensure proper sealing when boiling point is
reached.

OPERATION

The pressure cap allows the cooling system to oper-

ate at higher than atmospheric pressure. The higher
pressure raises the coolant boiling point; this allows
increased radiator cooling capacity.

The gasket in the cap seals the filler neck, so that

vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve con-
tainer.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE CAP TESTING

Dip the pressure cap in water. Clean any deposits

off the vent valve or its seat and apply cap to end of
the Pressure Cap Test Adaptor that is included with
the Cooling System Tester 7700 (Fig. 18). Working
the plunger, bring the pressure to 104 kPa (15 psi) on
the gauge. If the pressure cap fails to hold pressure
of at least 97 kPa (14 psi), replace the pressure cap.

CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm
that cap is bad.

If the pressure cap tests properly while positioned

on Cooling System Tester (Fig. 18), but will not hold
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.

Fig. 17 Cooling System Pressure Cap

1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
8 - FILLER NECK

Fig. 18 Testing Cooling System Pressure Cap

1 - PRESSURE CAP
2 - PRESSURE TESTER

PL/SRT-4

ENGINE - 2.0L SOHC

7 - 27

RADIATOR DRAINCOCK (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE RELIEF TESTING

WARNING: THE WARNING WORDS “DO NOT OPEN
HOT” ON THE PRESSURE CAP IS A SAFETY PRE-
CAUTION. WHEN HOT, THE COOLING SYSTEM
BUILDS UP PRESSURE. TO PREVENT SCALDING
OR OTHER INJURY, THE PRESSURE CAP SHOULD
NOT BE REMOVED WHILE THE SYSTEM IS HOT
AND/OR UNDER PRESSURE.

The pressure cap upper gasket to filler neck seal

can be checked by removing the overflow hose at the
filler neck overflow nipple (Fig. 19). Attach the radi-
ator pressure tester to the filler neck overflow
nipple, and pump air into the system. The pressure
cap upper gasket should relieve pressure at 69-124
kPa (10-18 psi), and hold pressure at 55 kPa (8 psi)
minimum.

There is no need to remove the pressure cap at any

time except for the following purposes:

• Check and adjust coolant freeze point

• Refill system with new coolant

• Conducting service procedures

• Checking for leaks

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT

15

MINUTES

BEFORE

REMOVING

CAP.

PLACE A SHOP TOWEL OVER THE CAP, AND WITH-
OUT

PUSHING

DOWN,

ROTATE

IT

COUNTER-

CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS
TO ESCAPE THROUGH THE OVERFLOW TUBE.
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS, PUSH DOWN ON THE CAP AND REMOVE
IT

COMPLETELY.

SQUEEZING

THE

RADIATOR

INLET HOSE WITH A SHOP TOWEL (TO CHECK
PRESSURE) BEFORE AND AFTER TURNING TO
THE FIRST STOP IS RECOMMENDED.

CLEANING

Use only a mild soap to clean the pressure cap.

INSPECTION

Hold the cap in your hand, top side up (Fig. 20).

The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.

Hold the cleaned cap in your hand, upside down.

If any light can be seen between vent valve and the
rubber gasket, replace the cap. Do not use a
replacement cap that has a spring to hold the
vent shut.

A replacement cap must be of the type designed for

coolant reserve systems. This design ensures coolant
return to the radiator.

Fig. 19 Cooling System Pressure Cap to Filler Neck

1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
8 - FILLER NECK

Fig. 20 Cooling System Pressure Cap

1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
8 - FILLER NECK

7 - 28

ENGINE - 2.0L SOHC

PL/SRT-4

COOLING SYSTEM PRESSURE CAP (Continued)

RADIATOR FAN

DESCRIPTION

The radiator fan is a single speed electric motor

driven fan. The radiator fan assembly components
includes an electric motor, a fan blade, and a support
shroud that is attached to the radiator. Each compo-
nent of the fan assembly can be serviced separately.

Depending on Engine/Transmission combination,

the vehicle may be equipped with a single fan (Fig.
21) or a dual fan (Fig. 22).

NOTE: Vehicles equipped with dual fans, each fan
blade is different from the other.

OPERATION

Radiator fan control operation is accomplished two

ways. The fan will always run when the air condi-
tioning compressor clutch is engaged. In addition to
this control, the fan is turned on by the temperature
of the coolant which is sensed by the coolant temper-
ature sensor which sends the message to the Power-
train Control Module (PCM). The PCM turns on the
fan through a fan relay by grounding the relay’s coil.
The fan relay is located in the Power Distribution
Center (PDC) (Fig. 23). Refer to the label beneath the
PDC cover for location of fan relay.

The PCM will actuate the fan relay whenever the

A/C clutch is engaged regardless of coolant tempera-
ture and vehicle speed. If the A/C clutch is not
engaged, the PCM will actuate the fan relay when
the coolant temperature reaches approximately (97°
C) 207° F and turns off the fan relay when the cool-
ant temperature drops to approximately (94°C) 201°
F. The fan relay is also turned off when the vehicle
speed is above approximately 100 Km/h (62 MPH).
For wiring diagrams of the fan circuit, (Refer to
Appropriate Wiring Information).

If the radiator fan is inoperative or a Diagnostic

Trouble Code (DTC) related to fan control has been
set, (Refer to Appropriate Diagnostic Information) for
complete diagnostic procedures.

Fig. 21 Single Radiator Fan Assembly

1 - SCREWS
2 - LOWER MOUNTS
3 - FAN MOTOR ELECTRICAL CONNECTOR

Fig. 22 Dual Radiator Fan Assembly

1 - MOUNTING SCREW LOCATIONS
2 - LOWER MOUNTS

Fig. 23 Power Distribution Center (PDC)

PL/SRT-4

ENGINE - 2.0L SOHC

7 - 29