Dodge Neon / Neon SRT-4. Manual — part 62
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
New developments in belt technology allow the belt
to greatly increase its life expectancy. Unless the belt
exhibits one of the following conditions do not replace
the belt.
• Excessive wear
• Frayed cords
• Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 6).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
NOTE: When installing drive belt on the pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
(1) Install the drive belt (Fig. 3) over all the pul-
leys except for the power steering pump pulley.
(2) Using a 17 mm wrench, rotate belt tensioner
clockwise (Fig. 2) until belt can be installed on the
power steering pulley. Release spring tension onto
belt.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 7). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
Fig. 5 Accessory Drive Belt Splash Shield
1 - CRANKSHAFT BOLT ACCESS PLUG
2 - RIGHT MOUNT BOLT ACCESS PLUG
3 - FASCIA
4 - SPLASH SHIELD
Fig. 6 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
7 - 6
ACCESSORY DRIVE - 2.0L SOHC
PL/SRT-4
DRIVE BELTS (Continued)
GENERATOR BELT
(1) Install belt around pulleys (Fig. 3).
(2) Adjust belt tension by tightening adjusting bolt
(Fig. 4). Adjust belt to specification shown in DRIVE
BELT TENSION CHART.
(3) Check belt tension using Special Tool 8371 –
Belt Tension Gauge Adapter, and the DRBIII
t using
the following procedures:
WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.
(a) Connect 8371 to the DRBIII
t following the
instructions provided with tool.
(b) Place end of microphone probe approximately
2.54 cm (1 in.) from belt at one of the belt center
span locations shown in (Fig. 8).
(c) Pluck the belt a minimum of 3 times. (Use
your finger or other suitable tool)
(d) The frequency of the belt in hertz (Hz) will
display on DRBIII
t screen.
(e) Adjust belt to obtain proper frequency (ten-
sion). Refer to DRIVE BELT TENSION CHART for
specifications.
(4) Tighten generator pivot bolt to 54 N·m (40 ft.
lbs.) (Fig. 4).
(5) Install accessory drive belt splash shield (Fig.
5).
(6) Lower vehicle.
(7) Tighten generator locking nut to 54 N·m (40 ft.
lbs.) (Fig. 4).
(8) Install power steering pump/air conditioning
compressor drive belt.
DRIVE BELT TENSION CHART
Accessory Drive
Belt
Belt Tension
Power Steering
Pump & A/C
Compressor
Dynamic Tensioned
Generator
New
135 lbs.
224 – 252
Hz
Used*
70 lbs.
172 – 181
Hz
*A belt is considered used after 15 minutes of run-in
time.
ADJUSTMENTS
For belt tension adjustment procedure, (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION)
Fig. 7 Belt Length Indicator Marks
1 - AUTOMATIC BELT TENSIONER
2 - BELT LENGTH INDICATOR
3 - MAXIMUM BELT LENGTH
4 - NOMINAL BELT LENGTH
5 - MINIMUM BELT LENGTH
Fig. 8 Belt Center Spans
PL/SRT-4
ACCESSORY DRIVE - 2.0L SOHC
7 - 7
DRIVE BELTS (Continued)
BELT TENSIONER
DESCRIPTION
The automatic belt tensioner (Fig. 9) maintains
proper tension on the power steering and air condi-
tioning belt. The tensioner is serviced with the
engine mount bracket assembly. The tensioner pulley
can be serviced separately.
REMOVAL
NOTE: Slight axial movement of the tensioner arm
is normal. Tensioner arm should move freely and
maintain 50–70 lb. tension on belt.
(1) Remove engine mount bracket assembly. (Refer
to
9
-
ENGINE/ENGINE
MOUNTING/ENGINE
MOUNT BRACKET - REMOVAL)
(2) Remove the tensioner pulley mounting bolt.
(3) Remove the pulley.
INSTALLATION
(1) Install tensioner pulley, dust shield, and bolt.
Tighten bolt to 27 N·m (20 ft. lbs.).
(2) Install engine mount bracket assembly. (Refer
to
9
-
ENGINE/ENGINE
MOUNTING/ENGINE
MOUNT BRACKET - INSTALLATION)
Fig. 9 Automatic Belt Tensioner
1 - GENERATOR BELT
2 - AUTOMATIC BELT TENSIONER
3 - POWER STEERING PUMP & A/C COMPRESSOR BELT
7 - 8
ACCESSORY DRIVE - 2.0L SOHC
PL/SRT-4
ENGINE - 2.0L SOHC
TABLE OF CONTENTS
page
page
ENGINE - 2.0L SOHC
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION . . . . . . . . . . . . . . . . . 18
LEVEL SERVICING . . . . . . . . . . . . . . . . . . . . 18
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . 18
ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 18
COOLING SYSTEM (2.0L SOHC) . . . . . . . . . . 19
COOLING SYSTEM (2.0L SOHC) . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . 20
COOLANT
. . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - COOLANT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLANT RECOVERY CONTAINER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE BLOCK HEATER
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE COOLANT TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE COOLANT THERMOSTAT
. . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING - ENGINE
. . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . 23
HEATER SUPPLY/RETURN TUBES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
HOSE CLAMPS
. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
RADIATOR DRAINCOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLING SYSTEM PRESSURE CAP
. . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP TESTING . . . . . . . 27
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE RELIEF TESTING . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . 28
RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 32
THERMOSTAT HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . 32
WATER PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - WATER PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . 33
PL/SRT-4
ENGINE - 2.0L SOHC
7 - 9
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