Dodge Neon (2005 year). Manual

Cooling System — Drain, Flush and Refill
At the intervals shown on the Maintenance Schedules,
the system should be drained, flushed and refilled.

If the solution is dirty or contains a considerable amount
of sediment, clean and flush with a reliable cooling
system cleaner. Follow with a thorough rinsing to remove
all deposits and chemicals. Properly dispose of old
antifreeze solution.

Selection Of Coolant
Use only the manufacturers recommended coolant, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct coolant type.

CAUTION!

Mixing of coolants other than specified HOAT en-
gine coolants, may result in engine damage and may
decrease corrosion protection. If a non-HOAT cool-
ant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.

Do not use plain water alone or alcohol base engine
coolant (antifreeze) products. Do not use additional
rust inhibitors or antirust products, as they may not
be compatible with the radiator engine coolant and
may plug the radiator.

This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propylene
Glycol based coolants is not recommended.

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MAINTAINING YOUR VEHICLE

Adding Coolant
Your vehicle has been built with an improved engine
coolant that allows extended maintenance intervals. This
coolant can be used up to 5 Years or 100,000 miles before
replacement. To prevent reducing this extended mainte-
nance period, it is important that you use the same
coolant throughout the life of your vehicle. Please review
these recommendations for using Hybrid Organic Addi-
tive Technology (HOAT) coolant.

When adding coolant, a minimum solution of 50% rec-
ommended Mopar Antifreeze/ Coolant 5 Year/100,000
Mile Formula HOAT (Hybrid Organic Additive Technol-
ogy), or equivalent, in water should be used. Use higher
concentrations (not to exceed 70%) if temperatures below

234°F (237°C ) are anticipated.

Use only high purity water such as distilled or deionized
water when mixing the water/engine coolant solution.
The use of lower quality water will reduce the amount of
corrosion protection in the engine cooling system.

Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.

NOTE:

Mixing coolant types will decrease the life of the

engine coolant and will require more frequent coolant
changes.

Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of
coolant, and to insure that coolant will return to the
radiator from the coolant recovery bottle.

The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.

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183

WARNING!

• The warning words “DO NOT OPEN HOT” on

the cooling system pressure cap are a safety pre-
caution. Never add coolant when the engine is
overheated. Do not loosen or remove the cap to
cool an overheated engine. Heat causes pressure
to build up in the cooling system. To prevent
scalding or injury, do not remove the pressure cap
while the system is hot or under pressure.

• Do not use a pressure cap other than the one

specified for your vehicle. Personal injury or
engine damage may result.

Disposal of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. To prevent ingestion by animals or children
do not store ethylene glycol based engine coolant in open
containers or allow it to remain in puddles on the
ground. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.

Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine idling, and warm to normal operating tempera-
ture, the level of the coolant in the bottle should be
between the ranges indicated on the bottle.

The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.

When additional coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.

Points To Remember

NOTE:

When the vehicle is stopped after a few miles (a

few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high

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MAINTAINING YOUR VEHICLE

humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot coolant to
enter the radiator.

If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.

• Do not overfill the coolant recovery bottle.
• Check coolant freeze point in the radiator and in the

coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.

• If frequent coolant additions are required, or if the

level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.

• Maintain coolant concentration at 50% HOAT engine

coolant (minimum) and distilled water for proper
corrosion protection of your engine which contains
aluminum components.

• Make sure that the radiator and coolant recovery

bottle overflow hoses are not kinked or obstructed.

• Keep the front of the radiator clean. If your vehicle is

equipped with air conditioning, keep the front of the
condenser clean, also.

• Do not change the thermostat for summer or winter

operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.

Hoses And Vacuum/Vapor Harnesses

Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, checking, tear, cuts, abrasions,
and excessive swelling indicate deterioration of the rub-
ber.

Pay particular attention to the hoses nearest to high heat
sources such as the exhaust manifold. Inspect hose rout-
ing to be sure hoses do not touch any heat source or
moving component that may cause heat damage or
mechanical wear.

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185

Insure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

Components should be replaced immediately if there is
any evidence of degradation that could cause failure.

Brake System

In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Section.

WARNING!

Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn’t have your full
braking capacity in an emergency.

Brake and Power Steering System Hoses
When servicing the vehicle for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, checking, tears, cuts, abrasions, and excessive
swelling suggest deterioration of the rubber. Particular
attention should be made to examining those hose sur-
faces nearest to high heat sources, such as the exhaust
manifold.

Inspect all hose clamps and couplings to make sure they
are secure and no leaks are present.

Insure nylon tubing in these areas has not melted or
collapsed.

NOTE:

Often, fluids such as oil, power steering fluid,

and brake fluid are used during assembly plant opera-
tions to ease the assembly of hoses to couplings. There-
fore, oil wetness at the hose-coupling area is not neces-
sarily an indication of leakage. Actual dripping of hot
fluid when systems are under pressure (during vehicle
operation) should be noted before hose is replaced based
on leakage.

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MAINTAINING YOUR VEHICLE

NOTE:

Inspection of brake hoses should be done

whenever the brake system is serviced and every engine
oil change.

WARNING!

Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.

Brake Master Cylinder
The fluid level in the master cylinder should be checked
when performing under hood services, or immediately if
the brake system warning lamp is on.

Be sure to clean the top of the master cylinder area before
removing the cap. If necessary, add fluid to bring the
fluid level up to the requirements described on the brake
fluid reservoir. Fluid level can be expected to fall as the
brake pads wear. Brake fluid level should be checked
when pads are replaced. However, low fluid level may be
caused by a leak and a checkup may be needed.

Use only manufacturers recommended brake fluid, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.

WARNING!

Use of a brake fluid that may have a lower initial
boiling point or unidentified as to specification, may
result in sudden brake failure during hard pro-
longed braking. You could have an accident.

Brake Fluid Master Cylinder

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187

WARNING!

Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.

Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter.

Do not allow petroleum based fluid to contaminate the
brake fluid as seal damage will result!

Automatic Transaxle

All front wheel drive vehicles have a transaxle and
differential assembly contained within a single housing.

Selection of Lubricant
It is important that the proper lubricant is used in the
transaxle to assure optimum transaxle performance. Use
only manufacturers recommended transmission fluid,
refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type. It is important that the
transmission fluid be maintained at the prescribed level
using the recommended fluid.

CAUTION!

Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.

Fluid Level Check
The fluid level in the automatic transaxle should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transaxle and of the fluid.

Procedure for Checking Fluid Level
Check the fluid level while the transmission is at normal
operating temperature. This occurs after at least 15 miles
(25 km) of driving. At normal operating temperature,
which is approximately 180°F ( 82°C), the fluid cannot be
held comfortably between the fingertips.

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MAINTAINING YOUR VEHICLE

To check the fluid level properly, the following procedure
must be used:

1. The vehicle must be on level ground.

2. The engine should be running at curb idle speed for a
minimum of 60 seconds.

3. Fully apply parking brake.

4. Place the gear selector momentarily in each gear
position ending with the lever in P (PARK).

5. Remove the dipstick, wipe it clean and reinsert it until
seated.

6. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be in the crosshatch
area at normal operating temperatures. If the fluid is low,
add as required into the dipstick tube. Do not overfill.

NOTE:

If it is necessary to check the transmission

below

the operating temperature, the fluid level should

be between the two COLD (lower) holes on the dipstick
with the fluid at approximately 80°F (27°C) (room tem-
perature). If the fluid level is correctly established at
room temperature, it should be between the HOT (upper)

reference holes when the transmission reaches 180°F
(82°C). Remember it is best to check the level at the
normal operating temperature.

If the fluid level shows low, add sufficient transmission
fluid to bring to the proper level.

MAINTAINING YOUR VEHICLE

189

CAUTION!

Do not overfill. Dirt and water in the transaxle can
cause serious damage. To prevent dirt and water
from entering the transaxle after checking or replen-
ishing fluid, make certain that the dipstick cap is
seated properly.

Fluid and Filter Changes
Automatic transmission fluid and filter should be
changed as follows:

Maintenance schedule “A”

— No change necessary.

Maintenance schedule “B”

– Every 60,000 miles (96 000

km) change fluid and filter under the following condi-
tions:

• Police, taxi, limousine, commercial type operation, or

trailer towing where the vehicle is driven regularly for
more than 45 minutes of continuous operation.

NOTE:

Refer to Section 8 of this manual for mainte-

nance schedules.

If the transaxle is disassembled for any reason, the fluid
and filter should be changed.

Special Additives
The manufacturer recommends against the addition of
any fluid additives to the transaxle. The only exception to
this policy is the use of special dyes to aid in detecting
fluid leaks. The use of transmission sealers should be
avoided as they may adversely affect seals.

Manual Transaxle

Lubricant Selection
Use only manufacturers recommended transmission
fluid, refer to Recommended Fluids, Lubricants and
Genuine Parts for correct fluid type.

Fluid Level Check
Check the fluid level by removing the fill plug. The fluid
level should be between the bottom of the fill hole and a
point not more that 3/16” (4.76 mm) below the bottom of
the hole.

Add fluid, if necessary, to maintain the proper level.

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MAINTAINING YOUR VEHICLE

Frequency of Fluid Change
Under normal operating conditions, the fluid installed at
the factory will give satisfactory lubrication for the life of
the vehicle. Fluid changes are not necessary unless the
following conditions exist:

• The lubricant has become contaminated with water. If

contaminated with water, the fluid should be changed
immediately.

• If severe usage has occurred, refer to Maintenance

Schedule “B” in Section 8 of this manual.

Appearance Care and Protection from Corrosion

Protection of Body and Paint from Corrosion
Vehicle body car requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
trees and road surfaces during other seasons, are highly
corrosive to the metal in you vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme

hot or cold weather and other extreme conditions will
have an adverse effect on paint, metal trim, and under-
body protection.

The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.

What Causes Corrosion?
Corrosion is the result of deterioration or removal of
paint and protective coatings from your vehicle.

The most common causes are:

• Road salt, dirt and moisture accumulation.
• Stone and gravel impact.
• Insects, tree sap and tar.
• Salt in the air near sea coast localities.
• Atmospheric fallout/industrial pollutants.

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191

Washing

• Wash your vehicle regularly. Always wash your ve-

hicle in the shade using a mild car wash soap, and
rinse the panels completely with clear water.

• If insects, tar or other similar deposits have accumu-

lated on your vehicle, wash it as soon as possible.

• Use Mopar auto polish to remove road film and stains

and to polish your vehicle. Take care never to scratch
the paint.

• Avoid using abrasive compounds and power buffing

that may diminish the gloss or thin out the paint
finish.

CAUTION!

Do not use abrasive or strong cleaning materials
such as steel wool or scouring powder, which will
scratch metal and painted surfaces. Many wheel
cleaners contain acids that may harm the wheel
surface.

Special Care

• If you drive on salted or dusty roads or if you drive

near the ocean, hose off the undercarriage at least once
a month.

• It is important that the drain holes in the lower edges

of the doors, rocker panels and rear deck lid be kept
clear and open.

• If you detect any stone chips or scratches in the paint,

touch them up immediately. The cost of such repairs is
considered the responsibility of the owner.

• Use Mopar touch up paint on scratches or chips as

soon as possible. Your dealer has touch up paint to
match the color of your vehicle.

• If your vehicle is damaged due to an accident or

similar cause which destroys the paint and protective
coating, have your vehicle repaired as soon as pos-
sible. The cost of such repairs is considered the respon-
sibility of the owner.

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MAINTAINING YOUR VEHICLE

• If you carry special cargo such as chemicals, fertilizers,

deicer salt, etc., be sure that such materials are well
packaged and sealed.

• If a lot of driving is done on gravel roads, consider

mud or stone shields behind each wheel.

Wheel And Wheel Trim Care
All wheels and wheel trim, especially Aluminum and
Chrome plated, should be cleaned regularly, using mild
soap and water to maintain their luster and to prevent
corrosion. Wash them with the same soap solution as the
body of your vehicle. Rinse wheels thoroughly.

When cleaning extremely dirty wheels, care must be
taken in the selection of tire and wheel cleaning chemi-
cals and equipment to prevent damage to the wheels.
Only Mopar Wheel Cleaners are recommended. Any of
the “DO NOT USE” items listed below can damage
wheels and wheel trim.

DO NOT USE:

• Any abrasive cleaner

• Any abrasive cleaning pad (such as steel wool) or

abrasive brush

• Any cleaner that contains an acid which can react with

and discolor the chrome surface.

CAUTION!

Many wheel cleaners contain acids that may harm
the wheel surface.

• Oven cleaner
• A car wash that uses carbide-tipped wheel cleaning

brushes or acidic solutions.

Interior Care
Use Mopar Fabric Cleaner to clean fabric upholstery and
carpeting.

Use Mopar Vinyl Cleaner to clean vinyl upholstery.

Mopar Vinyl Cleaner is specifically recommended for
vinyl trim.

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193

Your leather upholstery can be best preserved by regular
cleaning with a damp soft cloth. Small particles of dirt
can act as an abrasive and damage the leather upholstery
and should be removed promptly with a damp cloth.
Stubborn soils can be removed easily with a soft cloth
and Mopar Total Clean. Care should be taken to avoid
soaking your leather upholstery with any liquid. Please
do not use polishes, oils, cleaning fluids, solvents, deter-
gents, or ammonia based cleaners to clean your leather
upholstery. Application of a leather conditioner is not
required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes.
Many are potentially flammable, and if used in
closed areas they may cause respiratory harm.

Cleaning Headlights
Your vehicle has plastic headlights that are lighter and
less susceptible to stone breakage than glass headlights.

Plastic is not as scratch resistant as glass and therefore
different lens cleaning procedures must be followed.

To minimize the possibility of scratching the lenses and
reducing light output, avoid wiping with a dry cloth. To
remove road dirt, wash with a mild soap solution fol-
lowed by rinsing.

Do not use abrasive cleaning components, solvents, steel
wool or other aggressive material to clean the lenses.

Glass Surfaces
All glass surfaces should be cleaned on a regular basis
with any commercial household-type glass cleaner.
Never use an abrasive type cleaner. Use caution when
cleaning inside rear windows equipped with electric
defrosters. Do not use scrapers or other sharp instru-
ments which may scratch the elements.

Instrument Panel Cover
The instrument panel cover has a low glare surface which
minimizes reflections in the windshield. Do not use
protectants or other products which may cause undesir-
able reflections. Use soap and warm water to restore the
low glare surface.

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MAINTAINING YOUR VEHICLE

Cleaning Plastic Instrument Cluster Lenses
The lenses in front of the instruments in the vehicle are
molded in clear plastic. When cleaning the lenses, care
must be taken to avoid scratching the plastic.

1. Clean with a wet soft rag. A mild soap solution may be
used, but do not use high alcohol content of abrasive
cleaners. If soap is used, wipe clean with a clean damp
rag.

2. Dry with a soft tissue.

Seat Belt Maintenance
Do not bleach, dye or clean the belts with chemical
solvents or abrasive cleaners. This will weaken the fabric.
Sun damage will also weaken the fabric.

If the belts need cleaning, use a mild soap solution or
lukewarm water. Do not remove the belts from the
vehicle to wash them.

Replace the belts if they appear frayed or worn or if the
buckles do not work properly.

FUSES

Underhood Fuses (Power Distribution Center)

A Power Distribution Center is located in the engine
compartment; next to the battery. A label identifying the
components and circuits is located on the underside of
the cover.

Underhood Fuses (Power Distribution Center)

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195

MAXI

FUSE

Amp/Color

Items Fused

—

40 Amp/
Green

Headlamps

40 Amp/
Green

Ignition Run

30 Amp/Pink ABS Solenoid

30 Amp/Pink Radiator Fan

Spare

40 Amp/
Green

ABS Pump

30 Amp/Pink Starter

40 Amp/
Green

Electric Back Light (EBL)

MINI
FUSE

Amp/Color

Items Fused

Spare

20 Amp/
Yellow

IOD/Int Lighting/Radio

20 Amp/
Yellow

Power Outlet

15 Amp/Blue Hazard Flasher

15 Amp/Blue MTV

20 Amp/
Yellow

Electronic Automatic
Transaxle (EATX)

10 Amp/Red

Horn

Spare

20 Amp/
Yellow

Fog Lamp (Export Only)

20 Amp/
Yellow

ASD/Fuel Pump

10 Amp/Red

A/C Clutch

15 Amp/Blue Stop Lamps

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MAINTAINING YOUR VEHICLE

Interior Fuses

The fuse access panel is behind the end cover at the left
side of the instrument panel. To remove the panel, pull it
out, as shown. A diagram identifying the components
and circuits is located on the inside of the cover.

FUSE

Amp/Color

Items Fused

10 Amp/Red

Power Mirror/
Multifunction

20 Amp/
Yellow

Wiper Switch/Motor

20 Amp/
Yellow

Radio/Power Sunroof

15 Amp/Blue

Interior Lighting

10 Amp/Red

Airbag Run Only

20 Amp/
Yellow

HVAC Blower

10 Amp/Red

Backup Switch/EBL/
Temp/Comp

15 Amp/Blue

High Headlamp

10 Amp/Red

Airbag Run-Start

15 Amp/Blue

ABS Engine Run Start

10 Amp/Red

ARKEM Run Start

10 Amp/Red

Ignition Off/Run/ Start

20 Amp/
Yellow

Power Seat Height Adjust

20 Amp/
Yellow

ARKEM Door Locks

15 Amp/Blue

Exterior Lighting

25 Amp/
Natural

Headlamp

Interior Fuse Panel

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197

Dodge Neon (2005 year). Manual - part 12