DODGE NEON 2000 Service Repair Manual

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

Valve Spring Compressor C-3422-B
Spring Compressor Adaptor 6526
Cylinder Bore Indicator C-119
Front Crankshaft Seal Remover 6771
Front Crankshaft Seal Installer 6780
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Remover Insert C-4685-C2
Crankshaft Sprocket Installer 6792
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Connecting Rod Guides 8189
PL2.0L SOHC ENGINE 9 - 73
SPECIAL TOOLS (Continued)

Dolly 6135
Cradle 6710
Post Kit Engine Cradle 6848
Pressure Gauge C-3292
Dial Indicator C-3339
Driver Handle C-4171
Valve Spring Tester C-647
9 - 74 2.0L SOHC ENGINEPL
SPECIAL TOOLS (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
EXHAUST SYSTEM........................1
EXHAUST FLEX-JOINT COUPLING............1
CATALYTIC CONVERTER....................1
EXHAUST HEAT SHIELDS..................3
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS CHART.......4
REMOVAL AND INSTALLATION
EXHAUST PIPE AND MUFFLER..............4CATALYTIC CONVERTER....................7
CLEANING AND INSPECTION
EXHAUST SYSTEM........................8
ADJUSTMENTS
EXHAUST SYSTEM ALIGNMENT.............8
SPECIFICATIONS
TORQUE SPECIFICATION CHART.............8
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
The exhaust system consist of an under floor cata-
lytic converter, a close coupled catalytic converter
(ULEV only), intermediate pipe, and a muffler (Fig.
1).
EXHAUST FLEX-JOINT COUPLING
An exhaust flex-joint coupling is used to secure the
catalytic converter to the exhaust manifold by using
four fasteners and a gasket for sealing (Fig. 2). This
coupling actually moves back and forth as the enginemoves, 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 pipe.
CATALYTIC CONVERTER
An under-floor catalytic converter is used on all
three emission packages; Federal Emission, Low
Emission Vehicle (LEV) and Ultra Low Emission
Vehicle (ULEV) (Fig. 3). The ULEV emission package
utilizes two catalytic converters. One is a close-cou-
pled catalytic converter that is integral to the
Fig. 1 Exhaust System
1 ± CATALYTIC CONVERTER (UNDER FLOOR)
2 ± EXHAUST INTERMEDIATE PIPE
3 ± ISOLATORS4 ± MUFFLER
5 ± BAND CLAMP
6 ± BAND CLAMP
PLEXHAUST SYSTEM 11 - 1

exhaust manifold, the other is a unique under-floor
catalytic converter (Fig. 3).
The three-way catalytic converter simultaneously
converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are con-
verted into water (H2O) and carbon dioxide (CO2).
Oxides of Nitrogen (NOx) are converted into elemen-
tal Nitrogen (N) and water. The three-way catalyst is
most efficient in converting HC, CO and NOx at the
stoichiometric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for
efficient conversion of exhaust gases. When a high
oxygen content (lean) air/fuel ratio is present for an
extended period, oxygen content in a catalyst can
reach a maximum. When a rich air/fuel ratio is
present for an extended period, the oxygen content in
the catalyst can become totally depleted. When this
occurs, the catalyst fails to convert the gases. This is
known as catalyst ªpunch through.9
Catalyst operation is dependent on its ability to
store and release the oxygen needed to complete the
emissions-reducing chemical reactions. As a catalyst
deteriorates, its ability to store oxygen is reduced.
Since the catalyst's ability to store oxygen is some-
what related to proper operation, oxygen storage can
be used as an indicator of catalyst performance.
Refer to the appropriate Powertrain Diagnostic Pro-
cedure for diagnosis of a catalyst related Diagnostic
Trouble Code (DTC).
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
Fig. 2 Flex-Joint
1 ± BELLOWS
2 ± PROTECTIVE ENDCAPS
3 ± FLANGE
Fig. 3 Catalytic Converters
1 ± CATALYTIC CONVERTER (LEV EMISSION)
2 ± CLOSE-COUPLED CATALYTIC CONVERTER (ULEV
EMISSION)
3 ± UNDER-FLOOR CATALYTIC CONVERTER (ULEV EMISSION)
4 ± OXYGEN SENSORS5 ± OXYGEN SENSOR
6 ± CATALYTIC CONVERTER (FEDERAL EMISSION)
7 ± OXYGEN SENSOR
11 - 2 EXHAUST SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

catalytic converter. Failure of the catalytic converter
can occur due to temperature increases caused by
unburned fuel passing through the converter. This
deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and
exhaust restrictions.
The use of catalysts also involves some non-auto-
motive 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 temperatures
because of no air movement under the vehicle.
There is no regularly scheduled maintenance on
any DaimlerChrysler catalytic converter. 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.
EXHAUST HEAT SHIELDS
The heat shields (Fig. 4), (Fig. 5), and (Fig. 6) are
needed to protect both the vehicle and the environ-
ment from the high temperatures developed in the
vicinity of the catalytic converter.
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.
Fig. 4 Heat ShieldÐCatalytic Converter
1 ± NUT
2 ± NUT
3 ± HEAT SHIELD
Fig. 5 Heat ShieldÐIntermediate Pipe
1 ± UNDER BODY
2 ± SCREWS
3 ± HEAT SHIELD
Fig. 6 Heat ShieldÐEngine Wire Harness
1 ± HEAT SHIELD
2 ± NUT (QTY. 2)
PLEXHAUST SYSTEM 11 - 3
DESCRIPTION AND OPERATION (Continued)