belt DODGE NEON 1999 Service Workshop Manual

(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) 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.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Remove air cleaner inlet duct (Fig. 17)
(2) Remove ignition coil pack (Fig. 18).
(3) Remove the cylinder head cover bolts.
(4) Remove cylinder head cover from cylinder
head.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new cylinder head cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install cover assembly to head and tighten fas-
teners to 12 N´m (105 in. lbs.).
(3) Install ignition coil pack. Tighten fasteners to
23 N´m (200 in. lbs.).
SPARK PLUG TUBE
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 19). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
Fig. 17 Inlet Duct Removal
Fig. 18 Ignition Coil Pack
PL2.0L SOHC ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)

(4) Apply MopartStud and Bearing Mount or
equivalent to a new tube approximately 1 mm from
theendina3mmwide area.
(5) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard-
wood block and mallet until the tube is seated into
the bottom of the bore.
(6) Install cylinder head cover. Refer to procedure
outlined in this section.
SPARK PLUG TUBE SEALS
The spark plug tube seals are located in the cylin-
der head cover (Fig. 20). These seals are pressed into
the cylinder head cover to seal the outside perimeter
of the spark plug tubes. If these seals show signs of
hardness and/or cracking they should be replaced.
CAMSHAFT
NOTE: TO REMOVE CAMSHAFT THE CYLINDER
HEAD MUST BE REMOVED.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Remove the cylinder head cover. Refer to proce-
dure outlined in this section.
(3) Mark rocker arm shaft assemblies so that they
are installed in their original positions.
(4) Remove rocker arm shaft bolts. Refer to proce-
dure outlined in this section.
(5) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to procedures outlined in
this section.
(6) Remove rear timing belt cover.
(7) Remove cylinder head. Refer to procedure out-
lined in this section.
(8) Remove camshaft sensor and camshaft target
magnet.
(9) Remove camshaft from the rear of cylinder
head.
INSPECT CYLINDER HEAD FOR THE FOLLOWING:
NOTE:
²Check oil feed holes for blockage.
²Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
ing.
²Check camshaft bearing 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 cylinder 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 corresponding 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.
INSTALLATION
(1) Lubricate the camshaft journals with oil and
install camshaftwithoutrocker arm assemblies
installed.
(2) Install camshaft target magnet into the end of
the camshaft. Tighten mounting screw to 3.4 N´m (30
in. lbs.).
(3) Install camshaft position sensor and tighten
mounting screws to 9 N´m (80 in. lbs.).
(4) Measure camshaft end play using the following
procedure:
²Mount dial indicator C-3339 or equivalent, to a
stationary point on cylinder head (Fig. 21).
²Using a suitable tool, move camshaft to rear-
ward limits of travel.
Fig. 19 Servicing Spark Plug Tubes
Fig. 20 Spark Plug Tube Seals
9 - 22 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

²Zero the dial indicator.
²Move camshaft forward to limits of travel and
read dial indicator.
²End play travel: 0.13 - 0.33 mm (0.005 - 0.013
in.).
(5) Install front camshaft seal. Camshaft must be
installed before the camshaft seal is installed. Refer
to procedure outlined in this section.
(6) Install cylinder head. Refer to procedure out-
lined in this section.
(7) Install rear timing belt cover.
(8) Install camshaft sprocket and tighten to 115
N´m (85 ft. lbs.).
(9) Install timing belt tensioner and timing belt.
Refer to procedures outlined in this section.
(10) Install rocker arm assemblies in correct order
as removed. Tighten the rocker arm assemblies in
sequence shown in (Fig. 22) to 28 N´m (250 in. lbs.).
(11) Install cylinder head cover and tighten fasten-
ers to 12 N´m (105 in. lbs.).
(12) Install ignition coil pack and ignition cables.(13) 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.
ROCKER ARM/HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Identify the rocker arm shaft assemblies before
removal.
(3) Loosen the attaching fasteners. Remove rocker
arm shaft assemblies from cylinder head.
(4) Identify the rocker arms spacers and retainers
for reassembly. Disassemble the rocker arm assem-
blies by removing the attaching bolts from the shaft
(Fig. 23).
(5) Slide the rocker arms and spacers off the shaft.
Keep the spacers and rocker arms in the same loca-
tion for reassembly.
Fig. 21 Camshaft End Play
Fig. 22 Rocker Arm Shaft Tightening Sequence
Fig. 23 Rocker Arm Shaft Assemblies
PL2.0L SOHC ENGINE 9 - 23
REMOVAL AND INSTALLATION (Continued)

NOTE: Inspect the rocker arm for scoring, wear on
the roller or damage to the rocker arm (Fig. 24)
Replace if necessary. Check the location where the
rocker arms mount to the shafts for wear or dam-
age. Replace if damaged or worn. The rocker arm
shaft is hollow and is used as a lubrication oil duct.
Check oil holes for clogging with small wire, clean
as required. Lubricate the rocker arms and spacers.
Install onto shafts in their original position (Fig. 23).
INSTALLATION
CAUTION: Set crankshaft to 3 notches before TDC
before installing rocker arm shafts. Refer to Timing
Belt System and Camshaft Seal Service of this sec-
tion for procedure.
(1) Install rocker arm/hydraulic lash adjuster
assembly making sure that adjusters are at least
partially full of oil. This is indicated by little or no
plunger travel when the lash adjuster is depressed. If
there is excessive plunger travel. Place the rocker
arm assembly into clean engine oil and pump the
plunger until the lash adjuster travel is taken up. If
travel is not reduced, replace the assembly. Hydraulic
lash adjuster and rocker arm are serviced as an
assembly.
(2) Install rocker arm and shaft assemblies with
NOTCH in the rocker arm shafts pointing up and
toward the timing belt side of the engine (Fig. 25).
Install the retainers in their original positions on the
exhaust and intake shafts (Fig. 23).
CAUTION: When installing the intake rocker arm
shaft assembly be sure that the plastic spacers do
not interfere with the spark plug tubes. If the spac-
ers do interfere rotate until they are at the proper
angle. To avoid damaging the spark plug tubes, do
not attempt rotating the spacers by forcing down
the shaft assembly.(3) Tighten bolts to 28 N´m (250 in. lbs.) in
sequence shown in (Fig. 26).
HYDRAULIC LASH ADJUSTER NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster Noise - Diagnosis in
Standard Service Procedures, outlined in this Group.
Lash adjusters are replaced with the rocker
arm as an assembly.
VALVE SEALS AND SPRINGS IN VEHICLE
REMOVAL
(1) Remove rocker arm shafts assemblies as previ-
ously outlined in this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772A with adapter
6779 (Fig. 27) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 28).
Fig. 24 Rocker Arm Assemblies
Fig. 25 Rocker Arm Shaft Notches
Fig. 26 Rocker Arm Shaft Tightening Sequence
9 - 24 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install valve seal/valve spring seat assembly
as outlined in the Valve Installation procedure in this
section.
(2) Using Special Tool MD-998772A compress valve
springs only enough to install locks. Correct align-
ment of tool is necessary to avoid nicking valve stems
(air pressure required), piston at TDC.
(3) Install rocker arm shaft assemblies as previ-
ously outlined in this section.
(4) Install cylinder head cover as previously out-
lined in this section.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System.
(3) Remove air cleaner inlet duct and air cleaner
(Fig. 30), disconnect all vacuum lines, electrical wir-
ing and fuel lines from throttle body.(4) Remove throttle linkage.
(5) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.
(8) Remove power steering pump assembly and set
aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and bracket from engine.
(10) Remove cylinder head cover.
(11) Remove cam sensor and fuel injectors wiring
connectors.
(12) Remove intake manifoldSOHC ONLY.
Removal procedure outline in Group 11.
(13) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(14) Remove rocker arm shaft assemblies.
(15) Remove cylinder head bolts.
Fig. 27 Removing and Installing Valve Spring
Fig. 28 Valve Stem Oil Seal Tool
Fig. 29 Valve Spring Assembly
Fig. 30 Air Cleaner Inlet Duct
PL2.0L SOHC ENGINE 9 - 25
REMOVAL AND INSTALLATION (Continued)

For the rest of installation, reverse removal proce-
dure.
(3) 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.
TIMING BELT COVER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 33).
(3) Remove crankshaft vibration damper. Refer to
procedure outlined in this section for removal.
(4) Lower vehicle and place a jack under engine.
(5) Remove right engine mount. Refer to procedure
outlined in this section.
(6) Remove power steering pump assembly and set
aside.
(7) Remove right engine mount bracket (Fig. 34).
(8) Remove front timing belt cover (Fig. 35).
INSTALLATION
(1) Install front timing cover.
(2) Install engine mount bracket.
(3) Install power steering pump assembly.
(4) Install right engine mount. Refer to procedure
outlined in this section for installation.
(5) Remove jack from under engine.
(6) Install crankshaft vibration damper Refer to
procedure outlined in this section for installation.
(7) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(8) Raise vehicle on hoist and install right inner
splash shield.
Fig. 33 Right Inner Splash Shield
Fig. 34 Right Engine Mount Bracket
Fig. 35 Timing Belt Cover
PL2.0L SOHC ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT OIL SEAL
REMOVAL
CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.
(1) Remove front timing belt cover, timing belt and
tensioner assembly. Refer to procedures outlined in
this section.
(2) Remove camshaft sprocket bolt, with the Mod-
ified Special Tool C-4687-1 as shown in (Fig. 36).
(3) Hold camshaft sprocket with modified tool
while removing bolt. Remove sprocket from camshaft.
(4) Remove rear timing belt cover.
(5) Remove camshaft seal using Special Tool
C-4679±A (Fig. 37).
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper if necessary.
INSTALLATION
(1) Install camshaft seal flush with cylinder head
using Special Tool MD 998306 (Fig. 38).
(2) Install rear timing belt cover.
(3) Install camshaft sprocket retaining bolt. Hold
camshaft sprocket with Special Tool C-4687-1 (Fig.
36) and tighten bolt to 115 N´m (85 ft. lbs.).(4) Install timing belt tensioner, timing belt, and
front cover. Refer to procedures outlined in this sec-
tion.
TIMING BELTÐWITH HYDRAULIC TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
²Remove the access plug from the outer timing
belt cover (Fig. 39).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 40).Fig. 36 Modification to Special Tool
Fig. 37 Removing Camshaft Oil Seal
Fig. 38 Installing Camshaft Seal
9 - 28 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 41).
Fig. 39 Timing Belt SystemÐWith Hydraulic Tensioner
Fig. 40 Camshaft Timing Marks
Fig. 41 Right Inner Splash Shield
PL2.0L SOHC ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 42).
(4) Lower vehicle and place a jack under engine.
(5) Remove right engine mount. Refer to procedure
outlined in this section.
(6) Remove power steering pump assembly and set
aside.
(7) Remove right engine mount bracket (Fig. 43).
(8) Remove front timing belt cover (Fig. 44).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt.
(9) Loosen timing belt tensioner fasteners (Fig. 46)
and remove timing belt and tensioner.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 45).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
ÐSOHC ENGINE
(1) When tensioner is removed from the engine it
is necessary to compress the plunger into the ten-
sioner body.
(2) Place the tensioner into a vise equipped with
soft jaws and slowly compress the plunger (Fig. 47).
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
(3) When plunger is compressed into the tensioner
body install a 1.9 mm (5/64) Allen wrench or pin
Fig. 42 Crankshaft DamperÐRemoval
Fig. 43 Right Engine Mount Bracket
Fig. 44 Timing Belt Cover
Fig. 45 Tensioner Pulley Assembly
9 - 30 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

through the body and plunger to retain plunger in
place until tensioner is installed.
(4) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 48).
(5) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 49).
(6) Move crankshaft to 1/2 mark before TDC (Fig.
50) for belt installation.
(7) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.(8) Move crankshaft sprocket to TDC to take up
belt slack. Install tensioner to block but do not
tighten fasteners.
(9) Using a torque wrench on the tensioner pulley
apply 28 N´m (250 in. lbs.) of torque (Fig. 51).
(10) With torque being applied to the tensioner
pulley move the tensioner up against the tensioner
Fig. 46 Remove Timing Belt
Fig. 47 Compressing Timing Belt Tensioner
Fig. 48 Crankshaft Sprocket Timing
Fig. 49 Camshaft Timing Mark
Fig. 50 Adjusting Crankshaft Sprocket for Timing
Belt Installation
PL2.0L SOHC ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)