engine DODGE NEON 2000 Service Repair Manual

a 0.762 mm (0.030 in.) spacer under the valve spring
seat to bring spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster(s) to bleed down before rotating
cam.
CLEANING AND INSPECTION
INTAKE MANIFOLD
CLEAN AND INSPECT
Check for:
²Inspect manifold for cracks or distortions.
²Check for torn or missing O-rings at the mating
surface of the manifold (Fig. 125).
EXHAUST MANIFOLD
CLEAN AND INSPECT
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head.
(2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion.
Replace manifold if necessary.
CYLINDER HEAD AND CAMSHAFT JOURNALS
CLEANING
Remove all gasket material from cylinder head. Be
careful not to gouge or scratch the aluminum head
sealing surface. Clean all engine oil passages.
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean aluminum gasket
surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 126)
NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 126)
²Drill motor with 3M RolocyBristle Disc (white
or yellow) (Fig. 126)
CAUTION: Excessive pressure or high RPM can
damage the sealing surfaces. The mild (white, 120
grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
on cast iron surfaces with care.
Fig. 125 Intake Manifold O-Rings
1 ± INTAKE MANIFOLD O-RING GASKETS
Fig. 126 Proper Tool Usage For Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
PL2.0L SOHC ENGINE 9 - 63
DISASSEMBLY AND ASSEMBLY (Continued)

INSPECTING CYLINDER HEAD
Check cylinder head for flatness with a straight
edge. Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 127).
INSPECTING CAMSHAFT JOURNALS
Inspect cylinder head camshaft bearings for wear.
Check the camshaft journals for scratches and worn
areas. If light scratches are present, they may be
removed with 400 grit sand paper. If deep scratches
are present, replace the camshaft and check the cyl-
inder head for damage. Replace the cylinder head if
worn or damaged. Check the lobes for pitting and
wear. If the lobes show signs of wear, check the cor-
responding rocker arm roller for wear or damage.
Replace rocker arm/hydraulic lash adjuster if worn or
damaged. If lobes show signs of pitting on the nose,
flank or base circle; replace the camshaft.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of
the oil pump should be smooth. Replace pump cover
if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 128). If a 0.076 mm (0.003 inch.) feeler
gauge can be inserted between cover and straight
edge, cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301
inch.) or less (Fig. 129), or if the diameter is 79.95
mm (3.148 inches) or less, replace outer rotor.
(4) If inner rotor measures 7.64 mm (0.301 inch) or
less replace inner rotor (Fig. 130).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 131). If measurement is 0.39
Fig. 127 Checking Cylinder Head Flatness
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
Fig. 128 Checking Oil Pump Cover Flatness
1 ± OIL PUMP BODY
2 ± OIL PUMP COVER
3 ± OUTER ROTOR
4 ± INNER ROTOR
Fig. 129 Measuring Outer Rotor Thickness
Fig. 130 Measuring Inner Rotor Thickness
9 - 64 2.0L SOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
(6) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 132) is
0.203 mm (0.008 inch) or more, replace both rotors.(7) Place a straightedge across the face of the
pump housing, between bolt holes. If a feeler gauge
of 0.102 mm (0.004 inch) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 133).ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 60.7 mm (2.39 inches) it should test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 inches). Replace spring that fails to meet
specifications.
(10) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings, damaged
or missing oil pick-up tube O-ring, clogged oil pick-up
tube screen, clogged oil filter and stuck open pres-
sure relief valve or other reasons for oil pressure
loss.
CYLINDER BLOCK AND BORE
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Engine
Core Plugs in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
Fig. 131 Measuring Outer Rotor Clearance in
Housing
1 ± FEELER GAUGE
2 ± OUTER ROTOR
Fig. 132 Measuring Clearance Between Rotors
1 ± FEELER GAUGE
2 ± INNER ROTOR
3 ± OUTER ROTOR
Fig. 133 Measuring Clearance Over Rotors
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
PL2.0L SOHC ENGINE 9 - 65
CLEANING AND INSPECTION (Continued)

CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 134). If the cyl-
inder walls are badly scuffed or scored, the cylinder
block should be rebored and honed, and new pistons
and rings fitted. Whatever type of boring equipment
is used, boring and honing operation should be
closely coordinated with the fitting of pistons and
rings in order that specified clearances may be main-
tained.Refer to Honing Cylinder Bores outlined
in the Standard Service Procedures for specifi-
cation and procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 134). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
For specifications, refer to Engine Specifications in
this section.
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
The upper and lower torque struts need to be
adjusted together to assure proper engine positioning
and engine mount loading. Whenever a torque strut
bolt(s) is loosened, this procedure must be performed.
(1) Loosen the upper and lower torque strut
attaching bolt at the suspension crossmember and
shock tower bracket (Fig. 135).
(2) The engine position may now be adjusted by
positioning a suitable floor jack on the forward edge
of the transmission bell housing (Fig. 136).
NOTE: The floor jack must be positioned as shown
in (Fig. 136) to prevent minimal upward lifting of the
engine.(3) Carefully apply upward force, allowing the
upper engine to rotate rearward until the distance
between the center of the rearmost attaching stud on
the engine mount bracket (point ªAº) and the center
of the hole for the washer hose clip on the shock
tower bracket (point ªBº) is 119 mm (4.70 in.) (Fig.
137).
(4) With the engine held at the proper position,
tighten both the upper and lower torque strut bolts
to 118 N´m (87 ft. lbs.) (Fig. 135).
(5) Remove the floor jack.
Fig. 134 Checking Cylinder Bore Size
9 - 66 2.0L SOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

Fig. 135 Torque Strut Bolts
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET
3 ± TORQUE STRUT BRACKET
4 ± UPPER TORQUE STRUT5 ± CROSSMEMBER
6 ± LOWER TORQUE STRUT
7 ± BOLTS
8 ± RIGHT FENDER
Fig. 136 Floor Jack Positioning
1 ± WOOD BLOCK
2 ± FLOOR JACK
Fig. 137 Engine Position Measurement
PL2.0L SOHC ENGINE 9 - 67
ADJUSTMENTS (Continued)

SPECIFICATIONS
2.0L SOHC ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, SOHC
Number of Cylinders 4
Displacement 2.0 Liters
(122 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 83.0 mm
(3.268 in.)
Compression Ratio 9.8:1
Firing Order 1-3-4-2
Compression Pressure 1172±1551 kPa
(170±225 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons (Federal Emission)
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance 17.5 mm
(11/16 in.) from bottom of
skirt0.012±0.044 mm
(0.0004±0.0017 in.)
Weight 325±335 grams
(11.47±11.82 oz.)
Land Clearance
(Diametrical)0.734±0.797 mm
(0.029±0.031 in.)
Piston Length 64 mm
(2.520 in.)
Piston Ring Groove
Depth No. 13.989±4.188 mm
(0.157±0.165 in.)
Piston Ring Groove
Depth No. 24.462±4.661 mm
(0.176±0.184 in.)
DESCRIPTION SPECIFICATION
Piston Ring Groove
Depth No. 33.847±4.131 mm
(0.151±0.163 in.)
Pistons (Low Emission VehicleÐLEV/ULEV)
Piston Diameter 87.456±87.474 mm
(3.4432±3.4439 in.)
Clearance 10.42 mm
(0.42 in.) from bottom of
skirt0.018±0.50 mm
(0.0008±0.0020 in.)
Weight 320±329 grams
(11.29±11.60 oz.)
Land Clearance
(Diametrical)0.758±0.790 mm
(0.0299±0.0312 in.)
Piston Length 55.8 mm
(2.197 in.)
Piston Ring Groove
Depth No. 13.989±4.188 mm
(0.157±0.165 in.)
Piston Ring Groove
Depth No. 24.462±4.661 mm
(0.176±0.184 in.)
Piston Ring Groove
Depth No. 33.847±4.131 mm
(0.151±0.163 in.)
Piston Pins
Clearance in Piston 0.008±0.015 mm
(0.0003±0.0006 in.)
Clearance in Connecting
RodInterference
Diameter 21.000±21.003 mm
(0.8268±0.8269 in.)
End Play None
Length 74.75±75.25 mm
(2.943±2.963 in.)
Piston Rings
Ring GapÐTop
Compression Ring0.23±0.52 mm
(0.009±0.020 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐ2nd
Compression Ring0.49±0.78 mm
(0.019±0.031 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring GapÐOil Control
Steel Rails0.23±0.66 mm
(0.009±0.026 in.)
9 - 68 2.0L SOHC ENGINEPL

DESCRIPTION SPECIFICATION
Wear Limit 1.0 mm
(0.039 in.)
Ring Side ClearanceÐ
Compression Rings0.025±0.065 mm
(0.0010±0.0026 in.)
Wear Limit 0.10 mm
(0.004 in.)
Ring Side ClearanceÐOil
Ring Pack0.004±0.178 mm
(0.0002±0.0070 in.)
Ring WidthÐ
Compression Rings1.17±1.19 mm
(0.046±0.047 in.)
Ring WidthÐOil Ring
Pack2.854±3.008 mm
(0.1124±0.1184 in.)
Connecting Rod
Bearing Clearance 0.026±0.059 mm
(0.001±0.0023 in.)
Wear Limit 0.075 mm
(0.003 in.)
Bore DiameterÐPiston
Pin20.96±20.98 mm
(0.8252±0.8260 in.)
Bore DiameterÐ
Crankshaft End50.991±51.005 mm
(2.0075±2.0081 in.)
Side Clearance 0.13±0.38 mm
(0.005±0.015 in.)
Wear Limit 0.40 mm
(0.016 in.)
WeightÐTotal (Less
Bearing)543 grams
(1.20 lbs.)
Crankshaft
Connecting Rod Journal
Diameter47.9924±48.0076 mm
(1.8894±1.8900 in.)
Main Bearing Journal
Diameter51.9924±52.0076 mm
(2.0469±2.0475 in.)
Journal Out-of-Round
(Max.)0.0035 mm
(0.0001 in.)
Journal Taper (Max.) 0.0038 mm
(0.0001 in.)
End Play 0.09±0.24 mm
(0.0035±0.0094 in.)
Wear Limit 0.37 mm
(0.015 in.)
Main Bearing Diametrical
Clearance0.022±0.062 mm
(0.0008±0.0024 in.)DESCRIPTION SPECIFICATION
Rocker Arm Shaft
Rocker Arm Shaft
Diameter19.966±19.984 mm
(0.7861±0.7868 in.)
Rocker Arm Shaft Retainers
IntakeÐWidth 28.43±28.49 mm
(1.1193±1.1217 in.)
ExhaustÐWidth1&529.15±29.25 mm
(1.1477±1.1516 in.)
ExhaustÐWidth 2, 3, and
440.40±40.50 mm
(1.5906±1.5945 in.)
Rocker Arm/Hydraulic Lash Adjuster
Rocker Arm Inside
Diameter20.00±20.02 mm
(0.787±0.788 in.)
Rocker Arm Shaft
Clearance0.016±0.054 mm
(0.0006±0.0021 in.)
Body Diameter 22.949±22.962 mm
(0.9035±0.9040 in.)
Plunger Travel Minimum
(Dry)2.2 mm
(0.087 in.)
Dry LashÐIntake 1.17 mm
(0.046 in.)
Dry LashÐExhaust 1.28 mm
(0.050 in.)
Rocker Arm Ratio 1.4 to 1
Cylinder Head Camshaft Bearing Diameter
Journal No. 1 41.20±41.221 mm
(1.622±1.6228 in.)
Journal No. 2 41.60±41.62 mm
(1.637±1.638 in.)
Journal No. 3 42.0±42.02 mm
(1.653±1.654 in.)
Journal No. 4 42.4±42.42 mm
(1.669±1.670 in.)
Journal No. 5 42.8±42.82 mm
(1.685±1.6858 in.)
Camshaft
Journal Diameter
No. 1 41.128±41.147 mm
(1.619±1.6199 in.)
No. 2 41.528±41.547 mm
(1.634±1.635 in.)
PL2.0L SOHC ENGINE 9 - 69
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION
No. 3 41.928±41.947 mm
(1.650±1.651 in.)
No. 4 42.328±42.374 mm
(1.666±1.668 in.)
No. 5 42.728±42.747 mm
(1.682±1.6829 in.)
Bearing ClearanceÐ
Diametrical0.053±0.093 mm
(0.0027±0.003 in.)
Bearing Clearance (Max.
allowable)0.12 mm
(0.0047 in.)
End Play 0.05±0.39 mm
(0.002±0.015 in.)
Lift (Zero Lash)
Intake 7.2 mm
(0.283 in.)
Exhaust 7.03 mm
(0.277 in.)
Exhaust Valve Timing*
Closes (ATDC) 5.4É
Opens (BBDC) 43.7É
Duration 229.1É
Intake Valve Timing*
Closes (ABDC) 41.1É
Opens (ATDC) 13.9É
Duration 207.2É
Valve Overlap 84.8É
*All readings in crankshaft degrees, at 0.5 mm (0.019
in.) of valve lift.
Cylinder Head
Material Cast Aluminum
Gasket Thickness
(Compressed)1.15 mm
(0.045 in.)
Valve Seat
Angle 45É
Seat DiameterÐIntake 33 mm
(1.299 in.)
Seat DiameterÐExhaust 28 mm
(1.102 in.)
Runout (Max.) 0.05 mm
(0.002 in.)
Valve Seat WidthÐIntake
and Exhaust0.9±1.3 mm
(0.035±0.051 in.)DESCRIPTION SPECIFICATION
Service LimitÐIntake 2.0 mm
(0.079 in.)
Service LimitÐExhaust 2.5 mm
(0.098 in.)
Valve Guide
Diameter I. D. 5.975±6.000 mm
(0.235±0.236 in.)
Guide Bore Diameter
(Std.)11.0±11.02 mm
(0.4330±0.4338 in.)
Guide Height (spring seat
to guide tip)13.25±13.75 mm
(0.521±0.541 in.)
Valves
Face Angle Intake and
Exhaust45±45.5É
Head DiameterÐIntake 32.12±33.37 mm
(1.303±1.313 in.)
Head DiameterÐExhaust 28.57±28.83 mm
(1.124±1.135 in.)
Valve Margin
Intake 1.15±1.48 mm
(0.0452±0.0583 in.)
Service Limit 0.95 mm
(1/32 in.)
Exhaust 1.475±1.805 mm
(0.058±0.071 in.)
Service Limit 1.05 mm
(3/64 in.)
Valve Length (Overall)
Intake 114.69±115.19 mm
(4.515±4.535 in.)
Exhaust 116.94±117.44 mm
(4.603±4.623 in.)
Valve Stem Tip Height
Intake 45.01±46.07 mm
(1.77±1.81 in.)
Exhaust 43.51±44.57 mm
(1.71±1.75 in.)
Valve Stem Diameter
Intake 5.934±5.952 mm
(0.2337±0.2344 in.)
9 - 70 2.0L SOHC ENGINEPL
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION
Exhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25 mm
(0.010 in.)
Exhaust 0.0736±0.094 mm
(0.0029±0.0037 in.)
Max. Allowable 0.101 mm
(0.004 in.)
Service Limit 0.25 mm
(0.010 in.)
Valve Springs
Free Length (Approx.) 46.75 mm
(1.84 in.)
Nominal Force (Valve
Closed)331 N @ 39.8 mm
(70 lbs. @ 1.57 in.)
Nominal Force (Valve
Open)711 N @ 32.6 mm
(160 lbs. @ 1.28 in.)
Installed Height 40.18 mm
(1.580 in.)
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Camshaft Sensor
Pick-upÐBolts9.6 Ð 85
Camshaft SprocketÐBolt 115 85 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20 +
1¤4
turnÐ
Structural CollarÐBolts Refer to Procedure
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 34 25 Ð
ÐM11 Bolts 81 60 Ð
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts Refer to Procedure
Cylinder Head CoverÐ
Bolts12 Ð 105
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Drive Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine Mounting Refer to Procedure
Exhaust Manifold to
Cylinder HeadÐBolts23 Ð 200
Exhaust Manifold Support
Bracket (Federal and
LEV)
ÐM8 Nut 28 Ð 250
ÐM10 Bolt 54 40 Ð
ÐM12 Bolt 95 70 Ð
Exhaust Manifold Support
Bracket (ULEV)54 40 Ð
Engine Torque Strut
Bracket to EngineÐBolts61 45 Ð
Powertrain Bending
StrutÐFront
ÐLong Bolts 101 75 Ð
ÐShort Bolts 61 45 Ð
Intake ManifoldÐBolts 12 Ð 105
Oil Filter Adaptor 80 60 Ð
Oil Filter 20 15 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump to Block 28 Ð 250
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Pump Relief
ValveÐCap41 30 Ð
PCV Valve 5.6 Ð 50
Rocker Arm ShaftÐBolts 28 Ð 250
Spark Plugs 28 Ð 250
Timing Belt CoverÐBolts 12 Ð 105
Timing Belt Tensioner
AssemblyÐBolts28 Ð 250
Water PumpÐBolts 12 Ð 105
PL2.0L SOHC ENGINE 9 - 71
SPECIFICATIONS (Continued)

SPECIAL TOOLS
2.0L SOHC ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Remover/Installer C-4687
Camshaft Sprocket Remover/Installer Adapter
C-4687-1
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor MD-998772-A
Spring Compressor Adapter 6779
9 - 72 2.0L SOHC ENGINEPL