height DODGE NEON 1999 Service Repair Manual

SUSPENSION
CONTENTS
page page
FRONT SUSPENSION..................... 10
REAR SUSPENSION...................... 39WHEEL ALIGNMENT....................... 1
WHEEL ALIGNMENT
INDEX
page page
DESCRIPTION AND OPERATION
COMPETITION PACKAGE ALIGNMENT........ 2
WHEEL ALIGNMENT GENERAL
INFORMATION......................... 1
DIAGNOSIS AND TESTING
PRE-ALIGNMENT VEHICLE INSPECTION...... 5
SUSPENSION AND STEERING DIAGNOSIS.... 3SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT PROCEDURE.............. 5
SPECIFICATIONS
VEHICLE ALIGNMENT SPECIFICATIONS AT
CURB HEIGHT......................... 9
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT GENERAL INFORMATION
Proper vehicle wheel alignment is the proper
adjustment of all interrelated front and rear suspen-
sion angles (Fig. 1). These angles are what affects
the handling and steering of the vehicle when it is in
motion.
The method of checking a vehicle's front and rear
wheel alignment will vary depending on the type and
manufacturer of the equipment being used. Instruc-
tions furnished by the manufacturer of the equip-
ment being used should always be followed to ensure
accuracy of the alignment, except alignment specifi-
cations recommended by Chrysler Corporation
MUST ALWAYSbe used.
CAUTION: Do not attempt to modify any suspen-
sion or steering components by heating or bending
of the component.Wheel alignment adjustments should be made in
the following sequence, to ensure that an accurate
alignment is performed.
(1) Rear Wheel Toe Adjustment within specifica-
tions for both total toe and thrust angle.
(2) Front Wheel Toe Adjustment within specifica-
tions for total toe.
(3)To eis measured in degrees or inches and is
the distance that the front edges of the tires are
closer (or farther apart) than the rear edges (Fig. 1).
See Front Wheel Drive Specifications for correct front
and rear wheel Toe specifications.
(4)Thrust Angleis defined as the average of the
Toe settings on each rear wheel. If this measurement
is out of specification, re-adjust rear wheel Toe so
that each wheel has 1/2 of the total Toe measure-
ment. When re-adjusting, do not exceed the total Toe
specification.
PLSUSPENSION 2 - 1

PRE-ALIGNMENT VEHICLE INSPECTION
CAUTION: If the front suspension crossmember
shows any sign of impact damage, the steering col-
umn to steering gear coupling must be inspected.
Refer to Group 19 Steering in this service manual
for the inspection procedure.
Before any attempt is made to change or correct
the wheel alignment factors, the following inspection
and necessary corrections must be made on those
parts which influence the steering of the vehicle.
(1) Be sure the fuel tank is full when the wheel
alignment specifications are checked and or adjusted.
A full tank of fuel weighs approximately 75 pounds,
if the fuel tank is not full this reduction in weight
will affect the curb height of the vehicle and the
alignment specifications.
(2) Alignment specifications of a vehicle can be the
most accurately checked and set when the passenger
compartment and trunk of the vehicle are vacant
with the exception of the spare tire. People, luggage,
and any other appreciable weight will adversely
affect the checking and setting of the camber specifi-
cation.
(3) Check and if required, inflate all of the tires to
the recommended air pressure. All tires must be of
the same size and in good condition and have approx-
imately the same tread wear.Note the type of
tread wear on the tire, this will aid in diagnos-
ing problems. Refer to Group 22 Tires And
Wheels in this service manual for the tire wear
diagnosis.
(4) Check the front tire and wheel assemblies for
radial runout.
(5) Before beginning the alignment process,
inspect all suspension component fasteners for loose-
ness and/or loss of specified torque.
(6) Inspect the lower front ball joints and all steer-
ing linkage for looseness and any signs of wear and
or damage.
(7) Inspect the tie rod ends for looseness and any
signs of wear and or damage.
(8) Inspect the rubber bushings on all suspension
components for signs of wear or deterioration. If any
bushings show signs of wear or deterioration they
should be replaced prior to aligning the vehicle.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER CAMBER
Front and rear Caster and Camber settings on this
vehicle are determined at the time the vehicle isdesigned, by the location of the vehicle's suspension
components. This is called a Net Build vehicle and
results in no required adjustment of Caster and
Camber after vehicle is built or when servicing the
suspension components. Thus Caster and Camber are
not normally considered an adjustable specification
when performing an alignment on this vehicle.
Though Caster and Camber are not adjustable they
must be checked to ensure they meet vehicle specifi-
cations.
If front and or rear camber is found not to meet
the vehicle alignment specifications, it can be
adjusted using a Mopar Service Kit developed to
allow for camber adjustment. If a vehicle's front or
rear camber is found to be outside the specifications,
the vehicles suspension components should be
inspected for any signs of damage on bending.This
must be done before using the Mopar Service
Kit for setting camber to meet required specifi-
cation.
If a vehicles caster is not within manufacturers
alignment specifications, check for damaged suspen-
sion components or body parts. This type of damage
can cause component locations to move affecting
vehicle alignment.No adjustment can be made
for the Caster setting on this vehicle.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or any other
modification of the suspension components.
(1) Correctly position vehicle on alignment rack
and install all required equipment on vehicle, per the
alignment equipment manufacturers specifications.
(2) Center the steering wheel and lock in place
using a steering wheel clamp.
NOTE: Prior to reading each alignment specifica-
tion, jounce the front and rear of the vehicle an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Correctly jounce vehicle and read front and
rear alignment settings and compare to vehicle spec-
ifications for Camber, Caster and Toe. See Alignment
Specifications in this group of the service manual for
required specifications.If front and rear camber
readings are within required specifications pro-
ceed to step Step 3 in the Front And Rear Toe
Setting procedure. If Camber readings are not
within specifications refer to step Step 1 in the
following camber adjustment bolt package
installation procedure, for the front and rear
Camber adjustment procedure.
PLSUSPENSION 2 - 5
DIAGNOSIS AND TESTING (Continued)

SPECIFICATIONS
VEHICLE ALIGNMENT SPECIFICATIONS AT CURB HEIGHT
FRONT WHEEL ALIGNMENTACCEPTABLE ALIGNMENT
RANGE AT CURB HEIGHT*PREFERRED SETTING
CAMBER...................................... -0.4É to +0.4É +0.0É
**-2.4É to +0.4É (Use On S/C ACR
Only)
TOTAL
TOE.......................................
Specified In Degrees (See Note)0.3Éin to 0.1Éout 0.1É in
** 0.30É In To 0.70É Out (Use On
S/C ACR Only)
CASTER*...................................... +1.8É to +3.8É +2.8É
*Side To Side Caster Difference
Not To
Exceed.........................................1.0É or less 0.0É
REAR WHEEL ALIGNMENT ACCEPTABLE ALIGNMENT
RANGE AT CURB HEIGHT*PREFERRE SETTING
CAMBER....................................... -.75É to +0.25É -0.25É
** -1.00É to + 0.25É (Use On S/C
ACR Only)
TOTAL
TOE......................................
Specified In Degrees (See Note)
TOE OUT: When Backed On
Alignment Rack Is TOE In When
Driving0.3É in to 0.1É out 0.1É in
** 0.30É In To 0.50É Out (Use On
S/C ACR Only)
THRUST
ANGLE................................-0.10É to +0.10É
Note: Total Toe is the arithmetic sum of the left and right wheel Toe settings. Positive is Toe-in, negative is
Toe-out. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after
setting Toe. Left and Right Toe
must be equal to within 0.02 degrees.
* Setting the vehicles front and/or rear suspension alignment specifications outside of the preferred setting shown
on the chart above will caused rapid and excessive tire wear.
** The alignment specifications shown, are only for vehicles which are equipped with the ACR (Competition
Package) sales code. This specification is listed to show the adjustable range for the Camber and Toe on the front
and rear suspension of a vehicle with the Competition Package. These alignment specifications are only to be
used at the request of the vehicle owner and only when the vehicle is going to be used in a competition event.
The alignment is to be set back to the preferred setting before the vehicle is returned to normal operation.
PLSUSPENSION 2 - 9

INSTALL
(1) If inspection determines replacement of stabi-
lizer bar to lower control arm attachment link bush-
ings is required, replace bushings before installing
stabilizer bar. Refer to (Fig. 42) for proper orientation
of attaching link bushing components.
(2) If stabilizer bar to front crossmember bushings
require replacement at time of inspection, install new
bushings before installing stabilizer bar. Bushings
are replaced by opening slit on bushings and peeling
them off stabilizer bar. Install new bushings on sta-
bilizer bar, by spreading bushing at slit and forcing
them on stabilizer bar.Bushings must be installed
on stabilizer bar with slit in bushing facing
front of vehicle when stabilizer bar is installed
(Fig. 43).
(3) Position stabilizer bar into front crossmember,
so cutouts in stabilizer bar bushings are aligned with
raised bead in crossmember. Install stabilizer bar
bushing retainers onto crossmember aligning raised
bead on retainer with cutouts in bushings (Fig. 44).Do not tighten stabilizer bar bushing retainers
at this time.
(4) Align stabilizer bar attaching link and bushing
assemblies with attaching link mounting holes in the
lower control arms (Fig. 45). Install stabilizer bar
attaching links into both lower control arms. Install
the attaching link to stabilizer bar bushing and
retaining nut. Torque the stabilizer bar attaching
link nut (Fig. 45) to 28 N´m (21 ft. lbs.).
(5) Lower vehicle so the suspension is supporting
the total weight of the vehicle.
(6) With lower control arms of the vehicle at curb
height, tighten stabilizer bar bushing to crossmember
retainer attaching bolts to 28 N´m (21 ft. lbs.) torque.
Fig. 42 Stabilizer Bar Attaching Link Assembly
Bushing Orientation
Fig. 43 Correct Stabilizer Bar To Crossmember
Bushing Installation
Fig. 44 Stabilizer Bar To Crossmember Bushing
Position
Fig. 45 Stabilizer Bar Link To Control Arm
Attachment
2 - 24 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

(9) Loosen but do not remove at this time, the 2
strut assembly to knuckle attaching bolts (Fig. 19).
Then remove the lateral links to knuckle attaching
bolt (Fig. 19).
(10) Hold tension strut from turning by using a
large adjustable wrench on flat of tension strut (Fig.
20) and remove tension strut nut. Then remove nut,
tension strut retainer and rear tension strut bushing
from tension strut at rear knuckle (Fig. 20).
(11) Remove both rear knuckle to strut assembly
clevis bracket attaching bolts (Fig. 19). If vehicle is
equipped with a rear sway bar also remove the sway
bar link to strut mounting bracket (Fig. 19).
(12) Remove knuckle assembly from strut, by slid-
ing knuckle straight out of clevis bracket on strut
assembly. Then remove knuckle from tension strut.
INSTALL
(1) Insert tension strut, tension strut bushing and
tension strut retainer into knuckle. Then install
knuckle into clevis bracket on rear strut assembly.Be sure stepped area of bushing is squarely
seated into hole in knuckle.
CAUTION: The knuckle to strut assembly attaching
bolts are serrated and must not be turned during
installation. Tighten and torque nuts while holding
bolts stationary in knuckle.
(2) Install the 2 strut assembly clevis bracket to
knuckle attaching bolts and nuts (Fig. 19). Torque
the attaching bolts to 95 N´m (70 ft. lbs.).
(3) Install the lateral arms to knuckle attaching
bolt, washers and nut as shown in (Fig. 19).Do not
tighten the lateral link bolt at this time. The
vehicle must be at curb height when tightening
the lateral link bolts.
Fig. 17 Drum Brake Support Plate Mounting Bolts
Fig. 18 Disc Brake Adapter Mounting
Fig. 19 Knuckle To Strut And Lateral Arm Mounting
Bolts
Fig. 20 Tension Strut To Rear Knuckle Attachment
PLSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

(4) Install tension strut bushing, tension strut
retainer and nut on tension strut (Fig. 21).When
installing tension strut retainers, the retainers
must be installed on tension strut, with cupped
side of retainer facing away from bushing and
knuckle (Fig. 21).
(5) Position a large adjustable wrench on flat of
tension strut to keep it from turning, (Fig. 22) and
then torque tension strut nut to 95 N´m (70 ft. lbs.).
(6) On vehicles equipped with rear drum brakes,
install rear brake support plate assembly onto the
knuckle (Fig. 17). Install the 4 bolts (Fig. 17) attach-
ing rear brake support plate to rear knuckle. Torque
attaching bolts to 68 N´m (50 ft. lbs.).
(7) On vehicles equipped with rear disc brakes,
install the disc brake adapter on knuckle (Fig. 18)
Install the 4 bolts attaching the disc brake adapter to
knuckle (Fig. 18). Torque attaching bolts to 68 N´m
(50 ft. lbs.).(8) If vehicle is equipped with ABS brakes, install
speed sensor head into rear brake support plate or
disc brake adapter (Fig. 15). Tighten wheel speed
sensor mounting bolt to a torque of 7 N´m (60 in.
lbs.).
CAUTION: The hub/bearing retaining nut must be
tightened to but must not exceed its required
torque specification. The proper torque specifica-
tion of the retaining nut is critical to the life of the
hub bearing.
(9) Install rear hub and bearing assembly on
knuckle. Install hub and bearing assembly retaining
nut (Fig. 16), and torque to 217 N´m (160 ft. lbs).
(10) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. If vehicle is
equipped with rear drum brakes, install the brake
drum on hub.
(11) If vehicle is equipped with rear disc brakes,
install rear braking disc on hub. Carefully install
rear brake caliper over braking disc and install on
adapter. Tighten the caliper assembly to adapter
mounting bolts to 22 N´m (192 in. lbs.). Refer to Rear
Disc Brakes in Group 5 Brakes in this service man-
ual for required caliper installation procedure.
(12) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(13) Lower vehicle.
(14) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(15) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
LATERAL LINKS
The rear suspension lateral links (Fig. 23) are only
serviced as complete assemblies. The isolator bush-
ings used in the lateral links are not serviced as sep-
arate components. The rear lateral link assemblies
are unique, having different size bushings to accom-
modate the rear Toe adjustment cams. The rearward
lateral links, must be installed with small bushing
sleeve at knuckle and large bushing sleeve at rear
crossmember. This is required to accommodate the
rear Toe adjustment cam.
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 21 Tension Strut Bushings Installed On Tension
Strut
Fig. 22 Torquing Tension Strut Nut
2 - 48 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

link mounting bolt at crossmember MUST be
installed, with head of bolt facing rear of vehi-
cle. The long attaching bolt must be used at
rear crossmember and short bolt used at
knuckle.
(1) Install washer on short lateral link attaching
bolt. Then install short lateral link attaching bolt,
into lateral link having the same size bushing
sleeves. Then install lateral link, bolt and washer
onto knuckle as an assembly, with head of bolt facing
to front of vehicle (Fig. 24).
(2) Install lateral link with small and large bush-
ing sleeve, on lateral link attaching bolt in rear
knuckle (Fig. 24).Small bushing sleeve must be
installed on bolt in rear knuckle with large
bushing sleeve at crossmember of vehicle.
(3) Install washer and nut onto lateral link attach-
ing bolt at rear knuckle (Fig. 24).Do not tighten
the lateral link to rear knuckle attaching bolt
at this time.
(4) Install Toe adjustment cam on long lateral link
attaching bolt. Install long lateral link attaching bolt
and adjustment cam, into lateral link toward rear of
vehicle, having the large bushing sleeve. Then pass
lateral link attaching bolt into rear crossmember
(Fig. 26).Head of long lateral link to crossmem-
ber attaching bolt must face to rear of vehicle
when installed.
(5) Position forward rear lateral link against rear
crossmember (Fig. 26). Then pass the lateral link
attaching bolt through front lateral link bushing
sleeve.
(6) Install washer and nut onto lateral link attach-
ing bolt at rear crossmember (Fig. 26).Do not
tighten the lateral link to rear crossmember
attaching bolt at this time.
(7) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(8) Lower vehicle to the ground.
(9) With suspension supporting total weight of
vehicle, and lateral links at correct curb height,
torque both lateral link attaching bolts to 95 N´m (70
ft. lbs.).
(10) Check and reset rear wheel TOE to specifica-
tions if required. Refer to Front And Rear Toe Setting
Procedure in the Wheel Alignment Check And
Adjustment section in this group of the service man-
ual for the required Toe setting procedure.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY
DISASSEMBLY
The rear strut unit is not serviced and must be
replaced as an assembly if found to be defective. The
strut is available with 2 calibrations, be sure strut is
replaced with an assembly of the same calibration.
The components of the strut assembly listed below
are replaceable if found to be defective.
²Coil spring (Coil springs come in a standard rate
of 120 lb./in. be sure spring is replaced with a spring
of the same rate.)
²Dust shield
²Mount assembly
²Jounce Bumper
²Lower Spring Isolator
²Shaft Nut
(1) Remove strut assembly requiring service from
the vehicle. Refer to Strut Assembly Removal in Ser-
vicing Rear Struts, in this section of the service man-
ual.
(2) Position strut assembly in a vise (Fig. 27).
Using paint or equivalent, mark the strut unit, lower
spring isolator, spring and upper strut mount for
indexing of the parts at assembly.
(3) Position Spring Compressors, Special Tool
C-4838 on the strut assembly spring (Fig. 28). Com-
press coil spring until all load is removed from upper
strut mount assembly.
(4) Install Strut Rod Socket, Special Tool, L-4558A
or L-4558 on strut shaft nut (Fig. 29). Inserted a 10
mm socket through special tool and onto end of strut
shaft (Fig. 29) to keep strut shaft from turning.
Remove strut shaft nut from strut shaft.
(5) Remove washer (Fig. 30) between strut shaft
nut and upper strut mount and isolator.
(6) Remove upper strut mount assembly from strut
shaft and spring (Fig. 31).
Fig. 26 Lateral Link Attachment To Crossmember
2 - 50 SUSPENSIONPL
REMOVAL AND INSTALLATION (Continued)

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. 101).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 101) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 101).
(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. 102).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B 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 INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
(3) If valve stems are worn more than 0.05 mm
(.002 in.), replace valve.
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. 103). Refer to Valve Guide Specification
Chart for specifications. Replace guides if they are
not within specification.
(3) Check valve guide height (Fig. 104).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested Special Tool C-647. As an example,
the compression length of the spring to be tested is
Fig. 101 Oil Pressure Relief Valve
Fig. 102 Oil Pump
Fig. 103 Checking Wear on Valve GuideÐTypical
PL2.0L SOHC ENGINE 9 - 47

33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and lift compress-
ing lever to set tone device (Fig. 105). Pull on torque
wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The Following specifications
apply to both intake and exhaust valve springs.
²Valve Closed Nominal ForceÐ 67 lbs. @ 39.8 mm
(1.57 in.)
²Valve Open Nominal ForceÐ 160 lbs. @ 32.6 mm
(1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.(2) Inspect the remaining margin after the valves
are refaced (Fig. 106). Intake valves with less than
0.95 mm (1/32 inch.) margin and Exhaust valves
with less than 1.05 mm (3/64 inch) margin should be
discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For valve specifications see Valve Specifica-
tion Chart.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
²Intake valve seat diameter is 33 mm (1.299 in.)
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake Valve Exhaust Valve
5.975 - 6.000
mm (0.2352 -
0.2362 in.)5.975 - 6.000
mm (0.2352 -
0.2362 in.)
Valve Guide Clearance
Intake Valve Exhaust Valve
New: 0.023 - 0.066
mm (0.001 -
0.0025 in.)0.051 - 0.094
mm (0.002 -
0.0037 in.)
Service Limit: 0.25 mm (0.010 in.)
Fig. 104 Valve Guide Height
Fig. 105 Valve Spring Testing
Fig. 106 Intake and Exhaust Valve Refacing
9 - 48 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Exhaust valve seat diameter is 28 mm (1.102
in.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. The intake valve seat must be ser-
viced when the valve seat width is 2.0 mm (0.079 in.)
or greater. The exhaust valve seat must be serviced
when the valve seat width is 2.5 mm (0.098 in.) or
greater. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.75 to 1.25 mm
(0.030 to 0.049 in.) (Fig. 107).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust
valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for
intake valve over spring seat when installed in thehead (Fig. 108). The valve tip chamfer may need to
be reground to prevent seal damage when the valve
is installed.
CLEANING
Clean all valve guides, valves and valve spring
assemblies thoroughly with suitable cleaning solution
before reassembling.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 109). The valve stem
seals should be pushed firmly and squarely over
valve guide.
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.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 45 1/2É
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 107 Valve Seat Refacing
Fig. 108 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
Fig. 109 Valve Stem Oil Seal Tool
PL2.0L SOHC ENGINE 9 - 49
DISASSEMBLY AND ASSEMBLY (Continued)