Engine Controls - Remove/install/overhaul: Removal & Installation Dodge Neon I

Removal & Installation (SOHC)

Camshaft position sensor is mounted on rear of cylinder head. Remove air intake hose. Disconnect Engine Coolant Temperature (ECT) sensor and camshaft position sensor electrical connectors. Remove brake booster hose. Remove electrical connector from holder on end of valve cover. Remove camshaft position sensor mounting screws and camshaft position sensor. Remove target magnet mounting bolt and target magnet. To install target magnet, align tabs on magnet with holes in cylinder head. To complete installation, reverse removal procedure.

Removal & Installation

Remove cover from bottom of engine compartment (if applicable). Crankshaft position sensor is located in cylinder block above oil filter. Disconnect crankshaft position sensor electrical connector. Remove crankshaft position sensor mounting bolt and crankshaft position sensor. To install, reverse removal procedure.

Removal

Fuel pump is located inside fuel tank. Drain fuel from fuel tank. Remove drain tube cap located on top rear of fuel tank. Connect a hose to opening and drain fuel into an approved container. Disconnect fuel line from fuel pump. Disconnect electrical connector from fuel pump. Using a jack, support fuel tank. Remove fuel tank strap bolts. Lower tank slightly. Using Fuel Pump Module Ring Spanner (6856), remove fuel pump lock nut. Remove fuel pump and "O" ring from fuel tank.

Installation

Clean seal area on fuel tank. Position a NEW "O" ring on ledge between fuel tank threads and fuel pump opening. Insert fuel pump into fuel tank. Ensure fuel pump alignment tab sits in notch in fuel tank. Using Fuel Pump Module Ring Spanner (6856), tighten fuel pump lock nut. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-11358-S26492278522000111300000). The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Fuel pump module removal is not necessary.
2. Raise vehicle on hoist.
3. Disconnect fuel supply line at the Filter/Regulator nipple (refer to «QUICK-CONNECT FITTINGS»(ref-11358-S26565636842010051800000) ).
4. Depress locking spring tab on side of Fuel/Regulator (Scheme 1) and rotate 90° counter-clockwise and pull out.

Note. Make sure that the upper and lower O-rings are on the Filter/Regulator assembly.

Lightly lubricate the O-rings with engine oil.

1. Insert Filter/Regulator into the opening in the fuel pump module, align the two hold down tabs with the flange.
2. While applying downward pressure, rotate the Filter/Regulator clockwise until the spring tab engages the locating slot (Scheme 2)
3. Connect the fuel line to the Filter/regulator.
4. Lower vehicle from hoist.

Scheme 1

Scheme 2

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Disconnect fuel supply hose from fuel rail. Disconnect fuel injector electrical connectors. Remove fuel rail bolts. Remove fuel rail from engine. Remove fuel injector retaining clip and injector.

Install NEW "O" rings. Apply a small amount of engine oil to fuel system component "O" rings. DO NOT allow engine oil to enter fuel rail. To complete installation, reverse removal procedure.

1. O2S may be mounted in exhaust manifold or exhaust pipe depending on engine application. Some engines use 2 oxygen sensors. O2S is equipped with a permanent pigtail, which must be protected from damage during O2S servicing.
2. Disconnect O2S electrical connector. Using appropriate socket or crow foot wrench, remove O2S from exhaust system. Clean exhaust system threads. If O2S is to be reused, apply anti-seize compound to O2S threads.
3. A new O2S will already have anti-seize compound applied to threads. Install O2S and tighten sensor to specification. See the «TORQUE SPECIFICATIONS»(ref-11358-S17729437382000111300000) table. Connect O2S electrical connector. Place O2S wiring harness in clips as necessary.

When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.

1. Disconnect negative cable from battery.
2. Perform «FUEL SYSTEM PRESSURE RELEASE»(ref-11358-S26492278522000111300000) .
3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube.

1. Using a clean lint free cloth, clean the fuel tube nipple and retainer.
2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil.
3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard.
4. The quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not are not visible, the retainer was not properly installed (Scheme 7) Do not rely upon the audible click to confirm a secure connection..
5. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Removal (SFI)

1. Disconnect negative battery cable. Disconnect air intake ducting. Disconnect all necessary electrical connectors. Disconnect vacuum hoses.
2. Disconnect accelerator cable, cruise control cable (if equipped) and transmission control cable (if equipped). Remove brackets as necessary. Remove throttle body mounting bolts. Remove throttle body from engine.

Ensure gasket mating surfaces are clean. Install NEW throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .