belt DODGE NEON 1999 Service Manual PDF

pulley bracket and tighten fasteners to 31 N´m (275
in. lbs.) (Fig. 51).
(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed.
(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 51).
(13) Install front half of timing cover.
(14) Install engine mount bracket.
(15) Install power steering pump assembly.
(16) Install right engine mount. Refer to procedure
outlined in this section.
(17) Remove jack from under engine.(18) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 52).
(19) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(20) Raise vehicle on hoist and install right inner
splash shield.
(21) Lower vehicle and perform camshaft and
crankshaft timing relearn procedure as follows:
²Connect DRB scan tool to the data link (diagnos-
tic) connector. This connector is located in the pas-
senger 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.
Fig. 51 Adjusting Timing Belt Tension
Fig. 52 Crankshaft DamperÐInstallation
9 - 32 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH MECHANICAL 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. 53).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 54).
REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 55).
Fig. 53 Timing Belt SystemÐWith Mechanical Tensioner
Fig. 54 Camshaft Timing Marks
Fig. 55 Right Inner Splash Shield
PL2.0L SOHC ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)

(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 56).
(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. 57).
(8) Remove front timing belt cover (Fig. 58).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft.
(9) Inserta8mmAllen wrench into the belt ten-
sioner. Before rotating the tensioner insert the long
end of a 1/8º or 3 mm Allen wrench into the pin hole
on the front of the tensioner (Fig. 59). Rotate the ten-
sioner counterclockwise with the Allen wrench, while
pushing in lightly on the 1/8 in. or 3 mm Allen
wrench, until it slides into the locking hole.(10) Remove timing belt.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
Fig. 56 Crankshaft DamperÐRemoval
Fig. 57 Right Engine Mount Bracket
Fig. 58 Timing Belt Cover
Fig. 59 Timing Belt Removal
9 - 34 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATIONÐ
SOHC ENGINE
(1) 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. 60).
(2) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 60).
(3) Move crankshaft to 1/2 mark before TDC (Fig.
62) for belt installation.
(4) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.
(5) Move crankshaft sprocket to TDC to take up
belt slack.
(6) Remove the pin or 1/8º or 3 mm Allen wrench
from belt tensioner.
(7) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 63).
(8) Install front half of timing cover.
(9) Install engine mount bracket.
(10) Install power steering pump assembly and set
aside.
(11) Install right engine mount. Refer to procedure
outlined in this section.
(12) Remove jack from under engine.(13) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 64).
(14) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(15) Raise vehicle on hoist and install right inner
splash shield.
(16) Lower vehicle and 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
Fig. 60 Crankshaft Sprocket Timing
Fig. 61 Camshaft Timing Mark
Fig. 62 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 63 Crankshaft and Camshaft Timing
PL2.0L SOHC ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)

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 TENSIONERÐMECHANICAL
REMOVAL
(1) Remove timing belt. Refer to procedure out-
lined in this section.
(2) Remove tensioner assembly attaching bolts
(Fig. 65).
(3) Remove tensioner assembly.
CAUTION: The timing belt tensioner is serviced as
an assembly. To prevent premature timing belt fail-
ure, DO NOT separate the tensioner pulley from
mounting bracket.
INSTALLATION
(1) Install timing belt tensioner assembly. Tighten
attaching bolts to 28 N´m (250 in. lbs.).
(2) Install timing belt. Refer to procedure outlined
in this section.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove front engine mount bracket. Refer to
Engine MountÐFront, in this section for procedures.
(3) Remove powertrain bending strut.
(4) Remove structural collar from oil pan to tran-
saxle (Fig. 66).
(5) Remove transaxle lower dust cover.
(6) If equipped with air conditioning remove oil fil-
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.(7) Remove oil pan.
(8) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 67).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
Fig. 64 Crankshaft DamperÐInstallationFig. 65 Timing Belt Tensioner AssemblyÐRemoval/
Installation
Fig. 66 Structural CollarÐRemoval and Installation
9 - 36 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(4) Install oil filter and adaptor.
(5) Install transaxle lower dust cover.
(6) Install powertrain bending strut.
(7) Install front engine mount and bracket.
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(8) Install the structural collar (Fig. 66) using the
following 3 step torque sequence:
²Step 1: Install the collar to oil pan bolts and
tighten to 3 N´m (30 in. lbs.).
²Step 2: Install collar to transaxle bolts and
tighten to 108 N´m (80 ft. lbs.).
²Step 3: Final torque the collar to oil pan bolts to
54 N´m (40 ft. lbs.).
(9) Fill engine crankcase with proper oil to correct
level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Using Special Tool 1026 and Insert 6827±A,
remove crankshaft damper (Fig. 68).
(2) Remove outer timing belt cover and timing
belt. Refer to procedure outlined in this section.(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 69).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 70). Do not damage the seal contact area
on the crankshaft.
INSTALLATION
(1) Install new seal by using Tool 6780±1 (Fig. 71).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket (Fig. 72). Using
Special Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing you.
(4) Install timing belt and covers. Refer to Timing
Belt System in this section for installation.
Fig. 67 Oil Pan Sealing
Fig. 68 Crankshaft DamperÐRemoval
Fig. 69 Crankshaft SprocketÐRemoval
Fig. 70 Front Crankshaft Oil SealÐRemoval
PL2.0L SOHC ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

(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. 83).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 84)
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.).
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. 85).
(5) Remove oil pick-up tube.
(6) Remove oil pump (Fig. 86) 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. 87). 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.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
Fig. 83 Engine Oil Filter Adapter to Engine Block
Fig. 84 Engine Oil Filter
Fig. 85 Crankshaft SprocketÐRemoval
9 - 42 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(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. 88).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 89).
(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.
Fig. 86 Oil Pump and Tube
Fig. 87 Oil Pump Sealing
Fig. 88 Front Crankshaft SealÐInstallation
PL2.0L SOHC ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)

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. 90).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 91) for identification.(3) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 90). 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.
(6) After removal, install bearing cap on the mat-
ing rod.
(7) Piston and Rods are serviced as an assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 92).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.
PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 93).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
Fig. 89 Crankshaft SprocketÐInstallation
Fig. 90 Piston Markings
Fig. 91 Identify Connecting Rod to Cylinder
Fig. 92 Piston RingsÐRemoving and Installing
9 - 44 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(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.
CRANKSHAFT DAMPER
NOTE: If a gap is found in the crankshaft damper,
in the area where the Poly-V Generator belt rides
this is normal and is acceptable (Fig. 97).
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. 98).
(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827±A (Fig. 99).
INSTALLATION
(1) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 100).
(2) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(3) Raise vehicle on hoist and install right inner
splash shield.
Fig. 97 Weld Gap
Fig. 98 Right Inner Splash Shield
Fig. 99 Crankshaft DamperÐRemoval
Fig. 100 Crankshaft DamperÐInstallation
9 - 46 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)