lock DODGE NEON 1999 Service Repair Manual

(8) Install main bearing bedplate to engine block
bolts (1 ± 10) and torque each bolt to 81 N´m (60 ft.
lbs.) in sequence shown in (Fig. 79).
(9) Install main bearing bedplate to engine block
bolts (11 ± 20), with baffle studs in positions 12, 13
and 16 and torque each bolt to 30 N´m (22 ft. lbs.) in
sequence shown in (Fig. 79).
(10) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(11) Install oil pump. If crankshaft end play is to
be checked refer to service procedures in this section.
(12) Install crankshaft sprocket.
(13) Install oil filter adapter and filter.
(14) Install oil pan and structural collar. Refer to
procedures outlined in the section.
(15) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ring is in the groove on adapter. Align
roll pin into engine block and tighten assembly to 80
N´m (60 ft. lbs.) (Fig. 80).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 81)
avoid deforming the filter, install tool band strap
against the seam at the base of the filter. The seam,
joining the can to the base is reinforced by the
base plate.
(1) Turn counterclockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
Fig. 79 Main Bearing Caps/Bedplate Torque
Sequence
Fig. 80 Engine Oil Filter Adapter to Engine Block
Fig. 81 Engine Oil Filter
PL2.0L DOHC ENGINE 9 - 87
REMOVAL AND INSTALLATION (Continued)

OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove Timing Belt. Refer to procedure in this
section.
(3) Remove Oil Pan. Refer to procedure in this sec-
tion.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 82).
(5) Remove oil pick-up tube.(6) Remove oil pump (Fig. 83) and front crankshaft
seal.INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 84). Install oil ring into oil pump body
discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
Fig. 83 Oil Pump and Tube
Fig. 82 Crankshaft SprocketÐRemoval
Fig. 84 Oil Pump Sealing
9 - 88 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N´m
(250 in. lbs.)
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 85).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 86).
(8) Install oil pump pick-up tube and oil pan.
(9) Install Timing Belt. Refer to procedure outlined
in this section.
(10) Connect negative cable to battery.PISTON AND CONNECTING ROD
REMOVAL
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 87).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 88) for identification.
(3) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 87). These stamps will
be either a directional arrow or a weight identifica-
tion for the assembly. L is for light and H is for
heavy. These assemblies should all be the same
weight class. Service piston assemblies are marked
with a S and can be used with either L or H produc-
tion assemblies. The weight designation stamps
should face toward the timing belt side of the engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove connecting rod cap boltsDo not use
old bolts if reinstalling connecting rod.Push
each piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
Fig. 85 Front Crankshaft SealÐInstallation
Fig. 86 Crankshaft SprocketÐInstallation
Fig. 87 Piston Markings
Fig. 88 Identify Connecting Rod to Cylinder
PL2.0L DOHC ENGINE 9 - 89
REMOVAL AND INSTALLATION (Continued)

ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 92).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 93).Be sure position of rings does not
change during this operation.
(4) The weight stamp designation L or H will be in
the front half of the piston should face toward the
front of the engine for SOHC engine. The arrow
should face toward the front of the engine for DOHC
engine (Fig. 87).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(7) Install rod caps. InstallNewbolts and tighten
to 27 N´m (20 ft.lb.) Plus 1/4 turn.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
(1) To remove the relief valve, proceed as follows:
(2) Remove the threaded plug and gasket from the
oil pump (Fig. 94).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 94) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 94).
(4) Remove oil pump cover screws, and lift off
cover.(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 95).
VALVE SERVICE WITH CYLINDER HEAD REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool MD 998735 or equivalent.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 96). Refer to Valve Guide Specification
Fig. 93 Installing Piston
Fig. 94 Oil Pressure Relief Valve
Fig. 95 Oil Pump
PL2.0L DOHC ENGINE 9 - 91
REMOVAL AND INSTALLATION (Continued)

CAUTION: If oversize valves are used, there is only
one oversize valve available. The same stem seal is
used on both the standard and oversize valve.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 100). Make sure
measurements are taken from top of spring seat to
the bottom surface of spring retainer. If height is
greater than 38.75 mm (1.525 in.), install a 7.620
mm (0.030 inch.) spacer under the valve spring seat
to bring spring height back within specification.
(5) Install cam followers and camshaft as previ-
ously 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 or adjusters to bleed down
before rotating cam.
CLEANING AND INSPECTION
CYLINDER HEAD AND CAMSHAFT JOURNALS
INSPECTING CYLINDER HEAD
Cylinder head must be flat within 0.1 mm (0.004
inch) (Fig. 102).Inspect cylinder head camshaft bearings for wear.
Check 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.
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not to gouge or scratch the alumi-
num head sealing surface.
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. 103). 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. 104), or if the diameter is 79.95
mm (3.148 inches) or less, replace outer rotor.
(4) If inner rotor measures 7.64 mm (.301 inch) or
less replace inner rotor (Fig. 105).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 106). If measurement is 0.39
mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
Fig. 101 Valve Stem Oil Seal ToolFig. 102 Checking Cylinder Head Flatness
9 - 94 2.0L DOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

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 outlined in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 109). The cyl-
inder bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
inch) maximum. If the cylinder 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 maintained.Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 109). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart for specifications.
SPECIFICATIONS
2.0L DOHC
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
Clearance 17.5 mm (11/16 in.) from bottom of
skirt......0.018 - 0.050 mm (0.0007 - 0.0020 in.)
Weight........340 - 350 grams (11.99 - 12.34 oz.)
Head Land Clearance (Diametrical) . .0.740 - 0.803
mm (0.029 - 0.031 in.)
Piston Length..............64.8 mm (2.551 in.)
Piston Ring Groove Depth No. 1 .3.983 - 4.132 mm
(0.157 - 0.163 in.)
Fig. 108 Measuring Clearance Over Rotors
Fig. 109 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Max. Out-of-
RoundMax. Taper
87.5 mm (3.445
in.)0.051 mm
(0.002 in.)0.051 mm
(0.002 in.)
Standard Piston Size
87.463 - 87.481 mm (3.4434 - 3.4441 in.)
Piston to Bore Clearance
0.012 - 0.044 mm (0.0005 - 0.0017 in.)
Measurements taken at Piston Size Location.
9 - 96 2.0L DOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

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)

NOTE: When replacement is required on any com-
ponent of the exhaust system, you must use origi-
nal equipment parts (or their equivalent).
INSTALLATION
When assembling exhaust systemdo nottighten
clamps until components are aligned and clearances
are checked.
(1) Assemble catalytic convertor to exhaust mani-
fold connection. Use a new flange gasket (LEV only)
(Fig. 9) or (Fig. 10).
(2) Assemble exhaust pipe to catalytic convertor
and the support to the underbody
(3) Install the muffler to exhaust pipe and the sup-
ports to the underbody.
(4) Working from the front of system;
(5) Align and tighten the catalytic convertor to
exhaust manifold ball joint bolts to 27 N´m (20 ft.
lbs.) (Fig. 9) or flex-joint attaching nuts (LEV) to 28
N´m (250 in. lbs.).
(6) Align each component to maintain position and
proper clearance with underbody parts (Fig. 11) and
tighten band clamps to specifications (Fig. 12).
CAUTION: Band (Torca) clamps should never be
tighten such that the two sides of the clamps are
bottomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
its clamping force and must be replaced.
(7) Connect the downstream heated oxygen sensor
and lower the vehicle.
INTAKE MANIFOLDÐSOHC ENGINE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the fresh air inlet duct from air
cleaner (Fig. 15).
(4) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 13).
(5) Place the open end of fuel pressure release
hose, Special Tool C-4799-1, into an approved gaso-
line container. Connect the other end of hose to the
fuel pressure test port (Fig. 14). Fuel pressure will
bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1.
(6) Perform fuel system pressure release procedure
before attempting any repairs.
(7) Disconnect the fuel supply line quick connect at
the fuel tube assembly.
Fig. 11 Exhaust Clearance
Fig. 12 Band Clamp (Torca)
Fig. 13 Fuel Pressure Test Port
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifold. Clean all mating sur-
faces. Replace all seals, with new seals. All intakemanifold fasteners and washers are to be discarded
andNEWfasteners and washers are to be used.
(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 N´m (105 in. lbs.) in sequence
shown in (Fig. 20).
(2) Install intake manifold to water inlet support.
Tighten fastener (Fig. 20) to 12 N´m (105 in. lbs.).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.). Install transmission to throttle
body support bracket and tighten to 11.9 N´m (105
in. lbs.) at the throttle body first. Next tighten the
bracket at the transmission.
(7) Connect Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) wiring connector.
(8) Connect knock sensor connector, and wiring at
starter. Connect wiring harness to intake manifold
tab.
(9) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(10) Connect vacuum hoses to throttle body.
(11) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(12) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(13) Install clean air duct to air filter housing.
Tighten clamp to 3 N´m (30 in. lbs.).
(14) Connect negative cable to battery.
(15) Install fresh air duct to air cleaner and
tighten wing nut.
(16) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 18 Knock Sensor
Fig. 19 EGR Tube Assembly
Fig. 20 Intake Manifold Tightening Sequence
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.
29) to 28 N´m (250 in. lbs.).
(2) Install intake manifold onto cylinder head and
tighten fasteners to 28 N´m (250 in. lbs.) in sequence
shown in (Fig. 30).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect heater tube and hose to intake mani-
fold.
(7) Connect upper radiator hose and coolant recov-
ery hose.
(8) Connect coolant temperature sensor wiring con-
nector.
(9) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.).
(10) Connect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP) wiring connector.(11) Connect knock sensor connector and starter
wires. Connect wiring harness to heater tube tab.
(12) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(13) Connect vacuum hoses to throttle body.
(14) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(15) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(16) Install fresh air duct to air filter housing.
Tighten clamp to 3 N´m (25 in. lbs.).
(17) Connect negative cable to battery.
(18) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Remove air cleaner assembly and bracket.
(2) Remove exhaust manifold heat shield (Fig. 31).
(3) Disconnect upstream heated oxygen sensor con-
nector.
Fig. 29 Lower Intake Manifold to Upper Tightening
Sequence
Fig. 30 Intake Manifold To Cylinder Head Tightening
Sequence
Fig. 31 Exhaust Manifold Heat Shield
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)