DODGE NEON 1999 Service Repair Manual

TORQUE CHART 2.0L DOHC
DESCRIPTION TORQUE
Camshaft Sensor Pick-Up
Bolts....................9.6 N´m (85 in. lbs.)
Camshaft Sprocket
Bolt.....................115N´m(85ft.lbs.)
Connecting Rod Cap
Bolts..........27N´m(20ft.lbs.) Plus 1/4 Turn
CollarÐOil Pan to Transaxle
Step 1: Collar to Oil Pan Bolts . .3 N´m (30 in. lbs.)
Step 2: Collar to Transaxle Bolts.108 N´m (80 ft. lbs.)
Step 3: Collar to Oil Pan Bolts .54 N´m (40 ft. lbs.)
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts...........30N´m(22ft.lbs.)
M11 Main Cap Bolts.........81N´m(60ft.lbs.)
Crankshaft Damper
Bolt....................142 N´m (105 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)
Drive Plate to Crankshaft
Bolts.....................95N´m(70ft.lbs.)
Engine Mount Bracket
Bolts.....................41N´m(30ft.lbs.)
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................15N´m(130 in. lbs.)
Intake Manifold
Bolts....................28N´m(250 in. lbs.)
Oil Filter Adapter
Fastener..................80N´m(60ft.lbs.)
Oil Filter..................20N´m(15ft.lbs.)
Oil Pan
Bolts....................12N´m(105 in. lbs.)
Drain Plug.................34N´m(25ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .55 N´m (40 ft. lbs.)
Spark Plugs
Plug......................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner AssemblyÐMechanical
Bolts....................28N´m(250 in. lbs.)
Timing Belt Tensioner AssemblyÐHydraulic
Bolts....................31N´m(275 in. lbs.)
Timing Belt TensionerÐHydraulic
Bolts....................31N´m(275 in. lbs.)DESCRIPTION TORQUE
Timing Belt Idler Pulley
Bolt........................61N´m(45ft.lbs.)
Timing Belt Cover
Bolts M6.................12N´m(105 in. lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
SPECIAL TOOLS
2.0L DOHC
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Remover/Installer C-4687
9 - 98 2.0L DOHC ENGINEPL
SPECIFICATIONS (Continued)

Camshaft Sprocket Remover/Installer Adapter
C-4687-1
Camshaft Seal Installer MD-998713
Installer Crankshaft Damper 6792
Crankshaft Sprocket Remover Insert C-4685-C2
Valve Spring Compressor MD-998772-A
Adapter Spring Compressor 6779
Valve Spring Compressor C-3422-B
Cylinder Bore Indicator C-119
PL2.0L DOHC ENGINE 9 - 99
SPECIAL TOOLS (Continued)

Front Crankshaft Seal Remover 6771
Front Crankshaft Seal Installer 6780
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Installer 6792
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Pressure Gage C-3292
Valve Spring Tester C-647
9 - 100 2.0L DOHC ENGINEPL
SPECIAL TOOLS (Continued)

ENGINE
CONTENTS
page
1.8L SOHC ENGINE...................... 1
1.8L SOHC ENGINE
INDEX
page
GENERAL INFORMATION
1.8L SOHC ENGINE...................... 1
GENERAL INFORMATION
1.8L SOHC ENGINE
For service of the 1.8L SOHC engine refer to the
2.0L SOHC engine information except for the follow-
ing specifications.
GENERAL SPECIFICATIONS
Type .....................In-Line OHV, SOHC
Bore..............................83.0 mm
Stroke.............................83.0mm
Compression Ratio.....................10.0:1
Displacement......................1.8Liters
Firing Order........................1,3,4,2
Compression (Cranking)
Pressure.......1172-1551 kPa (170 - 225 psi)
Maximum Variation Between Cylinders......25%
Lubrication . . . Pressure Feed - Full Flow Filtration
(Crankshaft Driven Pump)
CYLINDER BORE AND PISTON
SPECIFICATIONS CHART
Standard Bore Maximum
Out-of-RoundMaximum
Taper
82.993 - 83.007
mm0.051 mm 0.051 mm
Standard Piston Size
82.974 - 82.956 mm
Piston to Bore Clearance
0.018 - 0.050 mm
Measurements Taken at Piston Size Location
PISTON RING SPECIFICATIONS
Ring Position Ring Gap Wear Limit
Upper Ring 0.23 - 0.38 mm 0.8 mm
Intermediate
Ring0.20 - 0.47 mm 1.0 mm
Oil Control Ring 0.25 -0.64 mm 1.0 mm
Ring Position Groove
ClearanceMaximum
Clearance
Upper Ring 0.03 - 0.07 mm 0.10 mm
Intermediate
Ring0.040 - 0.078
mm0.10 mm
OIL CONTROL RING (THREE PIECE) - OIL RING
SIDE RAILS MUST BE FREE TO ROTATE AFTER
ASSEMBLY
PLENGINE 9 - 1

ENGINE 1.8L SOHC
Cylinder Block
Cylinder Bore Diameter.....82.993 - 83.007 mm
Out-of-Round (Max.)...............0.051 mm
Taper (Max.).....................0.051 mm
Pistons
Clearance from Piston (measured 6.0 mm from
bottom of skirt) to bore.......0.018 - 0.050 mm
Weight.....................296-305grams
Land Clearance (Diametrical) . . 0.753 - 0.799 mm
Piston Length....................54.11 mm
Piston Ring Groove Depth No. 1
.........................3.203 - 3.337 mm
Piston Ring Groove Depth No. 2
.........................4.406 - 4.272 mm
Piston Ring Groove Depth No. 3
.........................3.932 - 3.798 mm
Piston Pins
Clearance in Piston..........0.009 - 0.021 mm
In Rod (Interference).........0.018 - 0.043 mm
Diameter................20.998 - 21.003 mm
End Play............................None
Length....................74.75 - 75.25 mm
Piston Rings
Ring Gap Top Compression Ring . . 0.23 - 0.38 mm
Ring Gap 2nd Compression Ring . . 0.20 - 0.47 mm
Ring Gap Oil Control (Steel
Rails)......................0.25 - 0.64 mm
Ring Side Clearance Compression Ring
Upper.........................0.03 - 0.07
Ring Side Clearance Compression Ring
Lower.....................0.04 - 0.078 mm
Oil Ring (Pack).............0.056 - 0.186 mm
Ring Width Compression Ring
Top ........................1.19 - 1.17 mm
Ring Width Compression Ring
Lower....................1.490 - 1.472 mm
Oil Ring (Pack).............2.984 - 2.854 mm
9 - 2 ENGINEPL
GENERAL INFORMATION (Continued)

EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER................... 4
EXHAUST BALL JOINT COUPLING.......... 1
EXHAUST FLEX-JOINT COUPLING (LEV)...... 2
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM.............................. 3
EXHAUST SYSTEMS...................... 1
HEAT SHIELDS.......................... 3
DESCRIPTION AND OPERATION
EXHAUST MANIFOLD..................... 3
INTAKE MANIFOLD DOHC................. 3
INTAKE MANIFOLD SOHC................. 3
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS CHART...... 4REMOVAL AND INSTALLATION
EXHAUST MANIFOLD.................... 11
EXHAUST PIPE AND MUFFLER............. 4
INTAKE MANIFOLDÐDOHC ENGINE......... 9
INTAKE MANIFOLDÐSOHC ENGINE......... 6
CLEANING AND INSPECTION
EXHAUST MANIFOLD.................... 12
INTAKE MANIFOLD DOHC................ 12
INTAKE MANIFOLD SOHC................ 12
SPECIFICATIONS
TORQUE CHART........................ 12
GENERAL INFORMATION
EXHAUST SYSTEMS
The exhaust system has an underfloor catalytic
converter, tail pipe, and muffler (Fig. 1).
EXHAUST BALL JOINT COUPLING
An exhaust ball joint coupling (Fig. 2) is used to
secure the exhaust pipe to the engine exhaust mani-
fold. This flexible joint moves back and forth as the
engine moves, preventing breakage that could occur
from the back-and-forth motion of a transverse
mounted engine.
Fig. 1 Exhaust System
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

The exhaust ball joint consists of two bolts, two
springs, and a ball joint seal ring, which is a sepa-
rate part from the exhaust pipe.
EXHAUST FLEX-JOINT COUPLING (LEV)
An exhaust flex-joint coupling is used on Low
Emission Vehicles (LEV) (Fig. 3). This coupling is
used to secure the catalytic converter to the exhaust
manifold. This coupling actually moves back and
forth as the engine moves, preventing breakage that
could occur from the back and forth motion of a
transverse mounted engine.
The exhaust flex-joint is welded to the catalytic
converter.
CATALYTIC CONVERTER
There is no regularly scheduled maintenance on
any Chrysler catalytic converter (Fig. 4). If damaged,
the converter must be replaced.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts.
The combustion reaction caused by the catalyst
releases additional heat in the exhaust system. Caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders if exhaust system is equipped with a
catalytic converter. Failure of the catalytic converter
can occur due to temperature increases caused by
unburned fuel passing through the converter.
The use of the catalysts also involves some non-au-
tomotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core. Do not allow
engine to operate above 1200 RPM in neutral for
extended periods over 5 minutes. This condition may
result in excessive exhaust system/floor pan temper-
atures because of no air movement under the vehicle.
Fig. 2 Ball Joint Connection
Fig. 3 Flex-Joint (LEV)
Fig. 4 Exhaust System ComponentsÐTypical
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
GENERAL INFORMATION (Continued)

HEAT SHIELDS
The heat shield (Fig. 5) is needed to protect both
the car and the environment from the high tempera-
tures developed in the vicinity of the catalytic con-
verter.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan heat shield on cars if equipped.
Light over-spray near the edges is permitted. Appli-
cation of coating will greatly reduce the efficiency
of the heat shields resulting in excessive floor pan
temperatures and objectionable fumes.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
To assist in the control of oxides of nitrogen (NOx)
in engine exhaust, some engines are equipped with
an exhaust gas recirculation system. The use of
exhaust gas to dilute incoming air/fuel mixtures low-
ers peak flame temperatures during combustion, thus
limiting the formation of NOx.
Exhaust gases are taken from the number four
exhaust port through a hole in the end of the cylin-
der head. REFER TO GROUP 25, EMISSION SYS-
TEMS FOR A COMPLETE DESCRIPTION,
DIAGNOSIS AND SERVICE PROCEDURES ON
THE EXHAUST GAS RECIRCULATION SYSTEM
AND COMPONENTS.
DESCRIPTION AND OPERATION
INTAKE MANIFOLD SOHC
The intake manifold is a molded plastic composi-
tion, attached to the cylinder head with ten fasten-
ers. This long branch design enhances low and
midrange torque. If removing the intake manifold for
any reason, the fasteners can not be reused.
INTAKE MANIFOLD DOHC
The intake manifold is a two piece aluminum cast-
ing, attached to the cylinder head with ten fasteners.
This long branch fan design enhances low and
midrange torque.
EXHAUST MANIFOLD
The exhaust manifold is made of nodular cast iron
for strength and high temperatures. Exhaust gasses
exit through a machined, articulated joint connection
to the exhaust pipe.
Fig. 5 Heat Shield Installation
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
GENERAL INFORMATION (Continued)

DIAGNOSIS AND TESTING
REMOVAL AND INSTALLATION
EXHAUST PIPE AND MUFFLER
REMOVAL
(1) Raise vehicle on hoist and apply penetrating oil
to band clamp fastener of component being removed
(Fig. 6).NOTE: Do not use petroleum-based lubricants
when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part.
A suitable substitute is a mixture of liquid dish
soap and water.
(2) Loosen band clamp and remove support insula-
tors at muffler (Fig. 7). Remove muffler from exhaust
pipe.
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve Leakage. 3. See Below:
(a) EGR valve to manifold gasket. (a) Tighten bolts and/or replace
gasket.
(b) EGR valve to EGR tube gasket. (b) Tighten bolts and/or replace
gasket.
(c) EGR tube to intake manifold
gasket.(c) Tighten bolts and/or replace
gasket.
4. Exhaust flex joint. (non LEV) 4. See Below:
(a) Spring height, not correctly
installed.(a) Check spring height, both sides
(specification is 32.5 mm, 1.28 inch)
look for source of spring height
variation if out of specification
(b) Exhaust sealing ring defective. (b) Inspect seal for damage on
round spherical surface. If no
damage is evident, check for
exhaust restriction causing high back
pressure on heavy acceleration.
5. Exhaust Flex joint to manifold
leak (LEV).5.Tighten nuts or replace gasket.
6. Exhaust flex joint (LEV). 6. Replace catalytic converter
assembly.
7. Pipe and shell noise from front
exhaust pipe.7. Characteristic of single wall pipes.
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten or replace clamps at
leaking joints.
2. Burned, blown, or rusted out
exhaust pipe or muffler.2. Replace muffler or exhaust pipes.
3. Restriction in muffler or tailpipe. 3. Remove restriction, if possible or
replace as necessary.
4. Catalytic converter material in
muffler.4. replace muffler and converter
assembly. Check fuel injection and
ignition systems for proper operation.
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLDPL

(3) Disconnect downstream heated oxygen sensor
from the catalytic converter pipe.
(4) Remove clamp at the catalytic converter to
exhaust pipe slip joint (Fig. 8). Separate at slip joint.
(5) When removing exhaust pipe, raise rear of
vehicle to relieve body weight from rear suspension
to provide clearance between pipe and lateral arms.
(6) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 9).
(7) Remove catalytic converter from vehicle.
Remove and discard flange gasket (LEV only).
(8) Clean ends of pipes and/or muffler to assure
mating of all parts. Discard broken or worn insula-
tors, rusted clamps, supports and attaching parts.
Fig. 6 Slip Joint ConnectionÐTypical
Fig. 7 Exhaust Pipe and Muffler Support
InsulatorsÐTypical
Fig. 8 Catalytic Converter to Exhaust Pipe
Connection
Fig. 9 Catalytic Converter to Exhaust Manifold
ConnectionÐFederal
Fig. 10 Catalytic Converter to Exhaust Manifold
ConnectionÐLEV
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)