Neon, 2000 - 2005

Routine Maintenance & Tune-Up

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Accessory Drive Belts



Accessory Belt Routing


Click image to see an enlarged view

Fig. Accessory drive belt routing-2.0L engines

Adjusting

CAUTION
Do not check belt tension with engine running.

Alternator Belt

Check belt tension using Special Tool 8371 - Belt Tension Gauge Adapter, and the DRBIII® using the following procedures:

  1. Connect 8371 to the DRBIII® following the instructions provided with tool.
  2.  
  3. Place end of microphone probe approximately 1 inch (2.54cm) from belt at one of the belt center span locations
  4.  
  5. Pluck the belt a minimum of 3 times. (Use your finger or other suitable tool).
    1. The frequency of the belt in hertz (Hz) will display on DRBIII® screen
    2.  

  6.  
  7. Adjust belt to obtain proper frequency (tension) by tightening the adjusting bolt and set belt tension to the following specifications:
    1. New: 135 lbs. (224 -252 Hz)
    2.  
    3. Used: 70 lbs. (172 -181 Hz)
    4.  

  8.  
  9. Tighten alternator pivot bolt and locking nut to 40 ft. lbs. (54 Nm).

    Click image to see an enlarged view

    Fig. Adjusting bolt (1), locking nut (2) and pivot bolt (3)

  10.  

Power Steering/Air Conditioning Belt

The automatic belt tensioner maintains proper tension on the power steering/air conditioning belt. After belt is installed, inspect belt length indicator marks. 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.

Click image to see an enlarged view

Fig. Automatic belt tensioner (1), belt length indicator (2), maximum belt length (3), nominal belt length (4) and minimum belt length (5)

Inspection

Inspect the drive belt for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately.

Removal & 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.

Alternator Belt
  1. Remove power steering pump/air conditioning compressor drive belt.
  2.  
  3. Loosen alternator locking nut.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Remove accessory drive belt splash shield.
  8.  
  9. Loosen alternator pivot bolt.
  10.  
  11. Loosen alternator adjusting bolt until alternator belt can be removed.
  12.  
  13. Remove alternator belt.

    Click image to see an enlarged view

    Fig. Adjusting bolt (1), locking nut (2) and pivot bolt (3)

  14.  

To install:

  1. Install belt around pulleys
  2.  
  3. Adjust belt tension by tightening adjusting bolt, refer to Adjustment procedure in this section.
  4.  
  5. Tighten alternator pivot bolt to 40 ft. lbs. (54 Nm).
  6.  
  7. Install accessory drive belt splash shield.
  8.  
  9. Lower vehicle.
  10.  
  11. Tighten alternator locking nut to 40 ft. lbs. (54 Nm).
  12.  
  13. Install power steering pump/air conditioning compressor drive belt.
  14.  

Power Steering And Air Conditioning Compressor Belt

NOTE
If removed, the alternator belt needs to be reinstalled before the power steering/air conditioner belt is installed.

  1. Using a 17mm wrench, rotate belt tensioner clockwise until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner.
  2.  
  3. Remove the drive belt

    Click image to see an enlarged view

    Fig. Rotating A/C and power steering belt tensioner

  4.  

To install:

  1. Install the drive belt over all the pulleys except for the power steering pump pulley.
  2.  
  3. Using a 17 mm wrench, rotate belt tensioner clockwise until belt can be installed on the power steering pulley. Release spring tension onto belt.
  4.  
  5. After belt is installed, inspect belt length indicator marks. Refer to the Adjustment procedure in this section.
  6.  

Firing Orders





Click image to see an enlarged view

Fig. 2.0L Engine Firing Order: 1-3-4-2 Distributorless ignition system

Fuel Filter



A combination fuel filter/pressure regulator assembly is used, which is located on the top of the fuel pump module.

Removal & Installation

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Disconnect the quick-connect fuel supply line from the filter/regulator nipple.
  8.  
  9. Depress the locking spring tab, located on the side of the fuel filter/regulator, then rotate 90 degrees and pull out. Be sure the upper and lower O-rings are still on the filter assembly.

    Click image to see an enlarged view

    Fig. Depress the spring tab, then rotate and pull the fuel filter assembly out

  10.  

To install:

  1. Lightly coat the filter O-rings with clean engine oil. Insert the filter into the opening in the fuel pump module, then align the 2 hold-down tabs with the flange.
  2.  
  3. While applying downward pressure, rotate the filter clockwise until the spring tab catches in the locating slot.
  4.  
  5. Attach the fuel line to the filter/regulator assembly.
  6.  
  7. Connect the negative battery cable.
  8.  

Idle Speed & Mixture Adjustments



Idle speed is maintained by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Ignition Timing



The ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Spark Plugs & Wires



Spark Plugs
Inspection and Gapping

Check the plugs for deposits and wear. If they are not going to be replaced, clean the plugs thoroughly. Remember that any kind of deposit will decrease the efficiency of the plug. Plugs can be cleaned on a spark plug cleaning machine, which can sometimes be found in service stations, or you can do an acceptable job of cleaning with a stiff brush. If the plugs are cleaned, the electrodes must be filed flat. Use an ignition points file, not an emery board or the like, which will leave deposits. The electrodes must be filed perfectly flat with sharp edges; rounded edges reduce the spark plug voltage by as much as 50%.

Check spark plug gap before installation. The ground electrode (the L-shaped one connected to the body of the plug) must be parallel to the center electrode and the specified size wire gauge (please refer to the Tune-Up Specifications chart for details) must pass between the electrodes with a slight drag.


NOTE
NEVER adjust the gap on a used platinum type spark plug.

Always check the gap on new plugs as they are not always set correctly at the factory. Do not use a flat feeler gauge when measuring the gap on a used plug, because the reading may be inaccurate. A round-wire type gapping tool is the best way to check the gap. The correct gauge should pass through the electrode gap with a slight drag. If you're in doubt, try one size smaller and one larger. The smaller gauge should go through easily, while the larger one shouldn't go through at all. Wire gapping tools usually have a bending tool attached. Use that to adjust the side electrode until the proper distance is obtained. Absolutely never attempt to bend the center electrode. Also, be careful not to bend the side electrode too far or too often as it may weaken and break off within the engine, requiring removal of the cylinder head to retrieve it.

Click image to see an enlarged view

Fig. A normally worn spark plug should have light tan or gray deposits on the firing tip



Click image to see an enlarged view

Fig. A carbon fouled plug, identified by soft, sooty, black deposits may indicate and improperly tuned vehicle. Check the air cleaner, ignition components and engine control system

Removal & Installation

When removing spark plugs, remove and install one at a time or label the ignition wires before removal to avoid mixing up the firing order.

If the engine has been run recently allow the engine to cool down before removing spark plugs.

Make sure ignition cables are routed correctly otherwise radio ignition noise, spark plug cross ignition or a short circuit to ground may result.

Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1 / 2 turn and pulling straight up in a steady motion.

  1. Disconnect ignition wire from ignition coil.
  2.  
  3. Disconnect spark plug cable from spark plug.
  4.  
  5. Use compressed air to clear debris from area around spark plug
  6.  
  7. Remove the spark plug using a quality socket with a rubber or foam insert.
  8.  

To install:

  1. Apply thin layer of anti-seize lubricant to spark plug threads.
  2.  
  3. To avoid cross threading, start the spark plug into the cylinder head by hand.
  4.  
  5. Tighten spark plugs to 13 ft. lbs. (17.6 Nm).
    CAUTION
    The tapered seat plugs are torque-critical! Do not exceed 13 ft. lbs. (17.6 Nm)!

  6.  
  7. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.
  8.  
  9. Reconnect to coil.
  10.  

 
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