DODGE NEON 1999 Service Repair Manual

2.0L DOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 59
ENGINE IDENTIFICATION NUMBER......... 58
ENGINE LUBRICATION SYSTEM............ 58
GENERAL SPECIFICATION................ 58
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 60
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 63
CYLINDER BORE AND PISTON SIZING....... 60
FITTING CONNECTING RODS.............. 62
FITTING CRANKSHAFT BEARINGS.......... 62
FITTING PISTON RINGS.................. 61
REMOVAL AND INSTALLATION
CAMSHAFT OIL SEALS................... 81
CAM FOLLOWER AND HYDRAULIC LASH
ADJUSTER ASSEMBLY.................. 69
CAMSHAFT............................ 67
CRANKSHAFT DAMPER.................. 73
CRANKSHAFT OIL SEALÐFRONT........... 82
CRANKSHAFT OIL SEALÐREAR............ 83
CRANKSHAFT.......................... 85
CYLINDER HEAD COVER................. 67
CYLINDER HEAD........................ 71
ENGINE ASSEMBLY...................... 65
ENGINE MOUNTÐFRONT................. 63
ENGINE MOUNTÐLEFT................... 63
ENGINE MOUNTÐRIGHT................. 64OIL FILTER ADAPTER.................... 87
OILFILTER ............................ 87
OILPAN ............................... 81
OIL PUMP............................. 88
PISTON AND CONNECTING ROD........... 89
POWER HOP DAMPER................... 64
STRUCTURAL COLLARÐ2.0L.............. 64
TIMING BELT COVER.................... 74
TIMING BELT TENSIONERÐMECHANICAL.... 80
TIMING BELTÐWITH HYDRAULIC TENSIONER . 75
TIMING BELTÐWITH MECHANICAL
TENSIONER.......................... 78
VALVE SPRING AND SEALSÐ
CYLINDER HEAD NOT REMOVED......... 69
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................. 91
VALVE SERVICE WITH CYLINDER HEAD
REMOVED........................... 91
CLEANING AND INSPECTION
CYLINDER BLOCK AND BORE............. 96
CYLINDER HEAD AND CAMSHAFT JOURNALS . 94
OIL PUMP............................. 94
SPECIFICATIONS
2.0L DOHC............................. 96
TORQUE CHART 2.0L DOHC............... 98
SPECIAL TOOLS
2.0L DOHC............................. 98
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
GENERAL SPECIFICATION
Type ..............In-Line OHV, DOHC & SOHC
Bore......................87.5mm (3.445 Inch)
Stroke.....................83.0mm (3.268 inch)
Compression Ratio.....DOHC - 9.6:1 SOHC - 9.8:1
Displacement..........2.0 Liters (122 Cubic Inch)
Firing Order.........................1,3,4,2
Compression Pressure.1172 - 1551 kPa (170 - 225 psi)
Maximum Variation Between Cylinders.......25%
Lubrication. . . .Pressure Feed - Full Flow Filtration
(Crankshaft Driven Pump)
Engine Oil Capacity.Refer to Group 0, Lubrication and
Maintenance
ENGINE LUBRICATION SYSTEM
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow fil-
ter (Fig. 2) to the main oil gallery running the length
Fig. 1 Engine Identification DOHC
9 - 58 2.0L DOHC ENGINEPL

of the cylinder block. A cylinder head restrictor,
located in the block, provides increased oil flow to the
main oil gallery (Fig. 3).MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylin-
der head bolt to an oil gallery running the length of
the cylinder head. The camshaft journals are par-
tially slotted to allow a predetermined amount of
pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam-
shaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
BLYA partial open deck is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4 mm. The bedplate
Fig. 2 Engine Lubrication Components
Fig. 3 Engine Lubrication System ÐDOHC Engine
PL2.0L DOHC ENGINE 9 - 59
DESCRIPTION AND OPERATION (Continued)

incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFTA nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 52 mm diameter
main and 48 mm diameter crank pin journals (all)
have undercut fillet radiuses that are deep rolled for
added strength. To optimize bearing loading 8 coun-
terweights are used. Hydrodynamic seals provide end
sealing, where the crankshaft exits the block.
Anaerobic gasket material is used for parting line
sealing. A sintered iron timing belt sprocket is
mounted on the crankshaft nose. This sprocket pro-
vides motive power; via timing belt to the camshaft
sprocket providing timed valve actuation.
PISTONSThe DOHC EngineDO NOThave pro-
vision for a free wheeling valve train. Non free
wheeling valve train means, in the event of a broken
timing belt Pistons will contact the Valves. All
engines use pressed-in piston pins to attach forged
powdered metal connecting rods. The connecting rods
are a cracked cap design and are not repairable. Hex
head cap screw are used to provide alignment and
durability in the assembly.
PISTON RINGSThe piston rings include a
molybdenum faced top ring for reliable compression
sealing and a taper faced intermediate ring for addi-
tional cylinder pressure control. Oil Control Ring
Package contains of 2 steel rails and a expander
spacer.
CYLINDER HEADFeatures a Dual Over Head
Camshaft (DOHC), 4 valves per cylinder cross flow
design. The valves are arranged in two in-line banks,
with the ports of the bank of two intake valves per
cylinder facing toward the radiator side of engine
and ports of the bank of two exhaust valves per cyl-
inder facing toward the dash panel. Incorporates
powder metal valve guides and seats. Integral oil gal-
leys within the cylinder head supplies oil to the
hydraulic lash adjusters, camshaft and valve mecha-
nisms.
CAMSHAFTSThe nodular iron camshafts have
six bearing journals and 2 cam lobes per cylinder.
Flanges at the rear journals control camshaft end
play. Provision for cam position sensor is located on
the intake camshaft at the rear of cylinder head. A
hydrodynamic oil seal is used for oil control at the
front of the camshaft.
VA LV E SFour valves per cylinder are actuated by
roller cam followers which pivot on stationary
hydraulic lash adjusters. All valves have 6 mm diam-
eter chrome plated valve stems. The valve sizes are
34.8 mm (1.370 inch.) diameter intake valves and
30.5 mm (1.20 inch.) diameter exhaust valves. Viton
rubber valve stem seals are integral with the springseats. Valve springs, spring retainers, and locks are
conventional.
INTAKE MANIFOLDThe intake manifold is a
two piece aluminum casting, attached to the cylinder
head with ten fasteners. This long branch fan design
enhances low and mid-speed torque.
EXHAUST MANIFOLDThe exhaust manifold is
made of nodular cast iron for strength and high tem-
peratures. Exhaust gasses exit through a machined,
articulated joint connection to the exhaust pipe.
COMPONENT REPLACEMENT
If any of the following parts have been changed or
replaced:
²Camshaft
²Camshaft Position Sensor
²Camshaft Position Sensor Target Magnet
²Cylinder Block
²Cylinder Head
²Water Pump
²Powertrain Control Module (PCM)
²Timing Belt and Timing Belt Tensioner
The camshaft and crankshaft timing relearn proce-
dure must be performed. Refer to the component
Removal and Installation procedure outlined in this
Group.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 4). The cylin-
der 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
9 - 60 2.0L DOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

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. 4). 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.
SIZING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin about 17.5 mm (11/16 inch) from the bot-
tom of the skirt as shown in (Fig. 5). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center lineshown in (Fig. 4). Refer to Cylinder Bore and Piston
Specifications Chart. Correct piston to bore clearance
must be established in order to assure quiet and eco-
nomical operation.
Chrysler engines use pistons designed specifically
for each engine model. Clearance and sizing locations
vary with respect to engine model.
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21ÉC (70ÉF).
FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 6).
Refer to Piston Ring Specification Chart.
Fig. 4 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Maximum
Out-of-RoundMaximum
Taper
87.5 mm (3.445
in.)0.051 mm
(0.002 in.)0.051 mm
(0.002 in.)
Standard Piston Size
87.457 - 87.475 mm (3.4432 - 3.4439 in.)
Piston to Bore Clearance
0.018 - 0.050 mm (0.0007 - 0.0020 in.)
Measurements Taken at Piston Size Location
Fig. 5 Piston Measurements
Fig. 6 Piston Ring Gap
PL2.0L DOHC ENGINE 9 - 61
SERVICE PROCEDURES (Continued)

(2) Check piston ring to groove side clearance (Fig.
7). Refer to Piston Ring Specification Chart.
FITTING CONNECTING RODS
(1) Follow the procedure specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance (Fig. 8). Refer to Connecting Rod Specification
Chart for specifications.
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
NOTE: The rod bearing bolts should not be reused.(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 9). Refer to Connecting Rod Specifica-
tion Chart for specifications.
FITTING CRANKSHAFT BEARINGS
Refer to Measuring Main Bearing Clearance in
Standard Service Procedures. Refer to Crankshaft
Specification Chart for specifications.
Fig. 7 Piston Ring Side Clearance
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Ring Gap Wear
LimitGroove Clearance Maximum Groove
Clearance
Upper Ring 0.23 - 0.52 mm
(0.009 - 0.020 in.)0.8 mm (0.031 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.49 - 0.78 mm
(0.019 - 0.031 in.)1.0 mm (0.039 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.23 - 0.66 mm
(0.009 - 0.026 in.)1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate After
Assembly
Fig. 8 Connecting Rod Bearing Clearance
Fig. 9 Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.026 - 0.059 mm (0.001 - 0.0023
in.)
Wear Limit: 0.075 mm (0.003 in.)
Connecting Rod Side Clearance
New Part: 0.13 - 0.38 mm (0.005 - 0.015 in.)
Wear Limit: 0.40 mm (0.016 in.)
9 - 62 2.0L DOHC ENGINEPL
SERVICE PROCEDURES (Continued)

CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 10).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart for specifications.
FEELER GAGE METHOD
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Donotloosen main bearing
cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
REMOVAL AND INSTALLATION
ENGINE MOUNTÐFRONT
(1) Raise vehicle on hoist.
(2) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(3) Remove the front engine mount thru-bolt from
the insulator and engine mount bracket (Fig. 11).
(4) Remove the mass damper. Remove the front
mount nuts and remove insulator assembly.
(5) Remove the engine mount bracket, if necessary.
(6) Reverse removal procedure for installation and
tighten fasteners in this order.
a. If engine mount bracket was removed, tighten
bolt 1 to 3 N´m (20 in. lbs.) and bolts 2, 3 and 4 to
108 N´m (80 ft. lbs.) (Fig. 11).
b. If engine mount bracket was removed, tighten
bolts 5 and 1 to 54 N´m (40 ft. lbs.).
c. Tighten engine mount bracket to insulator
assembly thru-bolt to 54 N´m (40 ft. lbs.).
d. Tighten insulator assembly nuts to the lower
radiator crossmember torque to 54 N´m (40 ft. lbs.).
e. Install mass damper and tighten to 54 N´m (40
ft. lbs.)
ENGINE MOUNTÐLEFT
(1) Raise vehicle on hoist and remove left front
wheel.
(2) Remove the Power Distribution Center (PDC)
on manual transaxle model, from battery tray mount
and lay aside.
(3) Support the transmission with a transmission
jack.
(4) Remove the thru-bolt access hole cover. Remove
the insulator thru-bolt from the mount (Fig. 12).
(5) Remove the transmission mount fasteners and
remove mount.
(6) Reverse removal procedure for installation.
Tighten fasteners in this order (Fig. 12):
²55 N´m (40 ft. lbs.)
²108 N´m (80 ft. lbs.)
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-PlayNew Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm (0.015 in.)
Main Bearing ClearanceNew Part: 0.022 - 0.062 mm (0.0008 - 0.0024 in.)
Connecting Rod Bearing
ClearanceNew Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.)
Wear Limit: 0.075 mm (0.003 in.)
Main Bearing Journal DiameterStandard: 52.00060.008 mm (2.047260.0003 in.)
1st Undersize: 51.98360.008 mm (2.046660.0003 in.)
Connecting Rod Journal
DiameterStandard: 48.00060.008 mm (1.889760.0003 in.)
1st Undersize: 47.98360.008 mm (1.889160.0003 in.)
Fig. 10 Checking Crankshaft End PlayÐ Dial
Indicator
PL2.0L DOHC ENGINE 9 - 63
SERVICE PROCEDURES (Continued)

ENGINE MOUNTÐRIGHT
(1) Remove the purge duty solenoid from engine
mount bracket.
(2) Remove the right engine mount insulator verti-
cal fasteners from frame rail (Fig. 13).
(3) Remove the load on the engine mounts by care-
fully supporting the engine and transmission assem-
bly with a floor jack.(4) Remove the thru-bolt access hole cover. Remove
the thru-bolt from the insulator assembly (Fig. 13).
Remove insulator.
(5) Reverse removal procedure for installation.
Tighten engine mount to rail fasteners to 54 N´m (40
ft. lbs.), then tighten engine mount to engine bracket
thru-bolt to 108 N´m (80 ft. lbs.).
POWER HOP DAMPER
NOTE: Power hop damper is used on manual trans-
mission vehicle only.
(1) Remove the thru-bolt and nut from the front
suspension crossmember (Fig. 14).
(2) Remove the damper nut and grommets.
Remove the damper.
(3) Remove the power hop damper bracket, if nec-
essary.
(4) Reverse removal procedure for installation.
Tighten all bolts and nuts to 54 N´m (40 ft. lbs.)
STRUCTURAL COLLARÐ2.0L
REMOVAL
(1) Raise vehicle on hoist.
NOTE: To remove transaxle dust cover, the front
bending strut must be removed.
(2) Remove structural collar from oil pan to tran-
saxle (Fig. 15).
INSTALLATION
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(1) Install the structural collar (Fig. 15) using the
following 3 step torque sequence:
Fig. 11 Engine MountingÐFront
Fig. 12 Engine MountingÐLeft
Fig. 13 Engine MountingÐRight
9 - 64 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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.).
(2) Lower vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect and remove battery and tray. Set
Powertrain Control Module (PCM) aside.
(3) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(4) Remove upper radiator hose, radiator and fan
module. Refer to Group 7, Cooling System for proce-
dure.
(5) Remove lower radiator hose.
(6) Disconnect automatic transmission cooler lines
and plug. If equipped.
(7) Disconnect clutch cable (Manual) and transmis-
sion shift linkage.
(8) Disconnect throttle body linkage.
(9) Disconnect engine wiring harness.
(10) Disconnect heater hoses.
(11) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(12) Hoist vehicle and remove right inner splash
shield (Fig. 16).
(13) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(14) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(15) Disconnect exhaust pipe from manifold.
(16) Remove front engine mount.
(17) Manual transmission: Remove power hop
damper.
Fig. 14 Power Hop Damper
Fig. 15 Structural CollarÐRemoval and Installation
Fig. 16 Right Inner Splash Shield
PL2.0L DOHC ENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)

(18) Lower vehicle. Remove air cleaner assembly.
(19) Remove power steering pump and reservoir,
Set them aside.
(20) Remove A/C compressor.
(21) Remove ground straps to body.
(22) Raise vehicle enough to allow engine dolly
and cradle Special Tools 6135 and 6710 to be
installed under vehicle.
(23) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 17). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(24) Install safety straps around the engine to cra-
dle tighten; straps and lock them into position.
(25) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(26) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(27) Remove engine and transmission mount thru-
bolts.
(28) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the cra-
dle to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Remove safety straps from engine and trans-
mission assembly. Slowly raise vehicle enough to
remove the engine dolly and cradle.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(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.
Fig. 17 Positioning Engine Cradle Support Post
Mounts
9 - 66 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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 ignition coil pack (Fig. 18).
(2) Remove the cylinder head cover fasteners (Fig.
19).
(3) Remove cylinder head cover from cylinder
head.
COVER INSTALLATION
NOTE: Before installation, clean cylinder head and
cover mating surfaces. Make certain the rails are
flat.
(1) Install new cylinder head cover gaskets.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.(2) Apply Mopar Silicone Rubber Adhesive Sealant
at the camshaft cap corners and at the top edges of
the 1/2 round seal.
(3) Install cylinder head cover assembly to head
and tighten fasteners in sequence shown in (Fig. 19).
Using the 3 step torque method:
²Step 1 Tighten all fasteners to 4.5 N´m (40 in.
lbs.)
²Step 2 Tighten all fasteners to 9.0 N´m (80 in.
lbs.)
²Step 3 Tighten all fasteners to 12 N´m (105 in.
lbs.)
(4) Install ignition coil pack. Tighten fasteners to
12 N´m (105 in. lbs.).
CAMSHAFT
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, timing belt tensioner, cam-
shaft sprockets, and timing belt covers. Refer to pro-
cedures outlined in this section.
(3) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 20).
(4) Loosen the camshaft bearing cap attaching fas-
teners in sequence shown in (Fig. 21); one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(5) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
Fig. 18 Ignition Coil Pack
Fig. 19 Cylinder Head Cover and Gasket
Fig. 20 Camshaft Bearing Cap Identification
PL2.0L DOHC ENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)