DODGE NEON 1999 Service Repair Manual

CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Mount dial indicator C-3339 or equivalent, to a
stationary point on cylinder head (Fig. 22).
(3) Using a suitable tool, move camshaft to rear-
ward limits of travel.
(4) Zero the dial indicator.
(5) Move camshaft forward to limits of travel and
read dial indicator.
(6) End play travel: 0.05 - 0.15 mm (0.002 - 0.06
in.).
INSTALLATION
NOTE: Check camshaft for binding in cylinder
head. Inspect camshaft bearing journals for dam-
age. If camshafts are binding, also check the cylin-
der head bearing surface for damage, and check
the camshaft bearing oil feed holes in the cylinder
head for clogging.Check the cam surface for abnormal wear and
damage, replace if defective. A visible worn groove
in the roller follower or on the cam lobes is cause
for replacement.
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate bearing journals and cam followers
with clean oil and install the camshafts. Install right
and left camshaft bearing caps #2 thru #5 and right
#6. Tighten M6 fasteners to 12 N´m (105 in. lbs.) in
sequence shown in (Fig. 23).
(2) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 24). Install bearing caps and
tighten M8 fasteners to 24 N´m (215 in. lbs.).
(3) Bearing cap number 1, must be installed before
the camshaft seals can be installed.
(4) Install rear timing cover, timing belt tensioner,
camshaft sprockets, timing belt, and front timing belt
covers. Refer to procedures outlined in this section.
Fig. 21 Camshaft Bearing CapÐRemoval
Fig. 22 Camshaft End Play
Fig. 23 Camshaft Bearing CapÐTightening
Sequence
Fig. 24 Camshaft Bearing Cap Sealing
9 - 68 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Install cylinder head cover using procedure out-
lined in this section.
(6) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Step 1: Connect 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.
²Step 2: Turn the ignition switch on and access
the ªmiscellaneousº screen.
²Step 3: Select re-learn cam/crank option and fol-
low directions on DRB screen.
CAM FOLLOWER AND HYDRAULIC LASH
ADJUSTER ASSEMBLY
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, sprockets and covers using
procedure outlined in this section.
(3) Remove camshaft. Refer to procedure previ-
ously outline this section.
(4) Remove cam follower assemblies from cylinder
head. Keep the cam followers in the order they have
been removed from the head for reassembly. Mark
hydraulic lash adjusters for reassembly in their orig-
inal position. Lash adjusters are serviced as an
assembly.
NOTE: Inspect the cam follower assembly for wear
or damage (Fig. 25). Replace as necessary.
INSTALLATION
(1) Install hydraulic lash adjuster assembly mak-
ing sure that adjusters are at least partially full of
oil. This is indicated by little or no plunger travel
when the lash adjuster is compressed. Lubricate with
clean oil and install cam follower assemblies in their
original position on the hydraulic adjuster and valve
stem (Fig. 26).
(2) Install the camshafts. Refer to procedure previ-
ously outlined in this section.
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.
Hydraulic lash adjusters are replaced as an
assembly and are not repaired.
VALVE SPRING AND SEALSÐCYLINDER HEAD
NOT REMOVED
REMOVAL
(1) Remove camshafts as previously 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 MD998772A with adapter
6779 (Fig. 27) compress valve springs and remove
valve locks.
(5) Remove valve spring.
Fig. 25 Cam Follower Assembly
Fig. 26 Cam Follower AssembliesÐInstallation
Fig. 27 Removing and Installing Valve Spring
PL2.0L DOHC ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 28).
INSTALLATION
(1) Install valve seal/valve spring seat assembly
(Fig. 29) as outlined in the valve installation proce-
dure in this section.
(2) Install valve spring and retainer. Using Special
Tool MD998772A compress valve springs only enough
to install locks. Correct alignment of tool is necessary
to avoid nicking valve stems (air pressure required),
piston at TDC.
(3) Remove air hose and install spark plugs.
(4) Install camshafts as previously outlined in this
section.
(5) Install valve cover as previously outlined in
this section.
Fig. 28 Valve Stem Oil Seal ToolFig. 29 Valve Stem Seal and Valve Spring Seat
Assemblies
9 - 70 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD
CYLINDER HEAD AND VALVE ASSEMBLY
PL2.0L DOHC ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)

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 duct and air cleaner, dis-
connect all vacuum lines, electrical wiring and fuel
line from fuel rail and 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 from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to procedure outlined in
this section.
(12) Remove inner timing belt cover.
(13) Remove cylinder head cover.
(14) Remove camshaft and cam follower assem-
blies. Refer to Camshaft Service for removal proce-
dure outlined in this section.
(15) Remove cylinder head bolts.
CAUTION: Use only a plastic scraper to remove
gasket material on the aluminum head sealing sur-
faces to prevent damage to cylinder head.
CYLINDER HEAD FLATNESS
(1) Cylinder head must be flat within 0.1 mm
(0.004 inch) (Fig. 30).
NOTE: Inspect camshaft bearing journals for scor-
ing.
INSTALLATION
(1) Position new cylinder head gasket onto block.
(2) Before installing the bolts the threads should
be oiled with engine oil. The 4 short bolts 110 mm
(4.330 in.) are to be installed in positions 7, 8, 9, and
10 (Fig. 31).
(3) Tighten the cylinder head bolts in sequence
shown in (Fig. 31). Follow the four step procedure
listed below:
²Step 1: Bolts1±6to34N´m(25ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)²Step 2: Bolts1±6to68N´m(50ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)
²Step 3: Bolts1±6to68N´m(50ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)
²Step 4: Turn all bolts an additional 90É (1/4
turn).Do not use a torque wrench for this step.
(4) Install cam follower assemblies and camshafts.
Refer to procedure outlined in this section.
(5) Install cylinder head cover. Refer to procedure
outlined in this section.
(6) Install inner timing belt cover and camshaft
sprockets.
(7) Install timing belt tensioner and timing belt.
(8) Connect electrical connectors to cam sensor and
fuel injectors.
(9) Install coil pack and connect electrical connec-
tor.
(10) Install power steering pump.
(11) Connect power brake booster hose to intake
manifold.
(12) Install throttle linkage to throttle body.
(13) Connect all vacuum lines and electrical con-
nectors to throttle body.
Fig. 30 Checking Cylinder Head Flatness
Fig. 31 Cylinder Head Tightening Sequence
9 - 72 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(14) Connect fuel supply hose to fuel rail.
(15) Install air cleaner duct and air cleaner.
(16) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(17) Raise vehicle and connect exhaust system to
exhaust manifold.
(18) Lower vehicle and connect negative cable to
battery.
(19) With DRB scan tool use ASD Fuel System
Test to pressurize fuel system. Check for fuel 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.
(20) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Step 1: Connect 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.
²Step 2: Turn the ignition switch on and access
the ªmiscellaneousº screen.
²Step 3: Select re-learn cam/crank option and fol-
low directions on DRB screen.
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. 32).
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 damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827±A (Fig. 34).
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. 35).
(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. 32 Weld Gap
Fig. 33 Right Inner Splash Shield
Fig. 34 Crankshaft DamperÐRemoval
PL2.0L DOHC ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)

TIMING BELT COVER
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotated after timing belt is removed. Damage to
valve components may occur. Always align timing
marks before removing timing 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. 36).(3) Remove crankshaft damper bolt. Remove
damper using Special Tool 1026 and Insert 6827±A or
equivalent (Fig. 37).
(4) Lower vehicle and place a jack under engine
(5) Remove right engine mount. Refer to procedure
outlined in this section
(6) Remove right engine mount bracket (Fig. 38)
(7) Remove timing belt cover fasteners, remove
cover (Fig. 38).
INSTALLATION
(1) Install front timing cover.
(2) Install engine mount bracket.
(3) Install Right engine mount. Refer to procedure
outlined in this section for installation.
(4) Remove jack from under engine.
(5) Install crankshaft vibration damper Refer to
procedure outlined in this section for installation.
(6)
Install accessory drive belts. Refer to Group 7,
Cooling System, Accessory Drive section for procedure.
(7) Raise vehicle on hoist and install right inner
splash shield.
Fig. 35 Crankshaft DamperÐInstallation
Fig. 36 Right Inner Splash Shield
Fig. 37 Crankshaft DamperÐRemoval
Fig. 38 Front Timing Belt Cover
9 - 74 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH HYDRAULIC TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
(1) Remove number one spark plug.
(2) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(3) Remove the timing belt access cover from the
engine (Fig. 39).
(4) Check the timing marks on the camshaft
sprockets, they should align with each other (Fig.
40).
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotate after timing belt is removed. Damage to valve
components may occur. Always align timing marks
before removing timing belt.
(1) Remove accessory drive belts. Refer to Group
07, Cooling System for procedures.(2) Raise vehicle on hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Refer to
Crankshaft Damper procedure outlined in this sec-
tion.
(4) Lower vehicle.
(5) Support engine with a jack and remove right
engine mount. Refer to procedure outline in this sec-
tion.
(6) Remove power steering pump assembly and set
aside.
(7) Remove engine mount bracket and timing belt
cover fasteners, remove cover.
Fig. 39 Timing Belt SystemÐDOHC With Hydraulic Tensioner
Fig. 40 Camshaft Timing Check
Fig. 41 Front Timing Belt Cover
PL2.0L DOHC ENGINE 9 - 75
REMOVAL AND INSTALLATION (Continued)

(8) Align camshaft timing marks. Loosen timing
belt tensioner fasteners and remove timing belt.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 42).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
ÐDOHC 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 and slowly com-
press the plunger (Fig. 43).
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 pin 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. 44).
(5) Set camshafts timing marks together by align-
ing notches on sprockets (Fig. 45).
(6) Rotate crankshaft 1/2 tooth counterclockwise
from TDC (Fig. 46).
(7) Install timing belt in this direction. Starting at
the crankshaft, go around the water pump sprocket,
idler pulley, camshaft sprockets and then around the
tensioner pulley (Fig. 47).
(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 to tensioner
(Fig. 47).
(10) With torque being applied to the tensioner
pulley move the tensioner up against the tensioner
pulley bracket and tighten fasteners to 31 N´m (275
in. lbs.).
Fig. 42 Tensioner Pulley Assembly
Fig. 43 Compressing Timing Belt Tensioner
Fig. 44 Crankshaft Sprocket Timing
Fig. 45 Camshaft Timing Marks
9 - 76 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed freely.(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 47).
(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. 48).
(19) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(20) Raise vehicle on hoist and install right inner
splash shield.
(21) Lower vehicle and perform camshaft and
crankshaft timing relearn procedure as follows:
²Step 1: Connect 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.
²Step 2: Turn the ignition switch on and access
the ªmiscellaneousº screen.
²Step 3: Select re-learn cam/crank option and fol-
low directions on DRB screen.
Fig. 46 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 47 Adjusting Timing Belt Tension
Fig. 48 Crankshaft DamperÐInstallation
PL2.0L DOHC ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)