wheel DODGE NEON 2000 Service Repair Manual

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play. 5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round
or worn.6. Replace crankshaft or grind
journals.
7. Loose flywheel or torque
converter.7. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
PLENGINE 9 - 13
DIAGNOSIS AND TESTING (Continued)

CRANKSHAFT
A nodular cast iron crankshaft is used. The engine
has five main bearings. The number three main is
flanged to control thrust. The mains and connecting
rod journals have undercut fillet radiuses that are
deep rolled for added strength. To optimize bearing
loading, eight counterweights are used. Hydrody-
namic seals provide end sealing, where the crank-
shaft 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 transmits crankshaft movement, via timing
belt to the camshaft sprocket providing timed valve
actuation.
PISTONS
The engineDOES NOThave provision 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. The engine uses pressed-in
piston pins to attach forged powdered metal connect-
ing 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. Pistons and connecting rods are serviced as
an assembly.
PISTON RINGS
The piston rings include a molybdenum faced top
ring for reliable compression sealing and a taper
faced intermediate ring for additional cylinder pres-
sure control. Oil Control Ring Package consist of two
steel rails and an expander spacer.
CYLINDER HEAD
The aluminum cylinder head features a Single
Over Head Camshaft (SOHC), four-valves per cylin-
der, cross flow design. The valves are arranged in
two inline banks, with the two intake per cylinder
facing toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFT
The nodular iron camshaft has five bearing jour-
nals and three cam lobes per cylinder. Provision for a
cam position sensor is provided on the camshaft at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVES
Four valves per cylinder are actuated by roller
rocker arms/hydraulic lash adjusters assemblies
which pivot on rocker arm shafts. All valves have
chrome plated valve stems. Viton rubber valve stem
seals are integral with spring seats. Valve springs,
spring retainers, and locks are conventional design.
INTAKE MANIFOLD
The intake manifold is a molded plastic composi-
tion, attached to the cylinder head with five fasten-
ers. This long branch design enhances low and mid-
range torque.
EXHAUST MANIFOLD
The exhaust manifold is made of nodular cast iron
for strength and high temperatures. Exhaust gasses
exit the manifold into an articulated joint connection
and 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 in this section.
9 - 16 2.0L SOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

(3) Carefully apply upward force, allowing the
upper engine to rotate rearward until the distance
between the center of the rearmost attaching stud on
the engine mount bracket (point ªAº) and the center
of the hole for the washer hose clip on the shock
tower bracket (point ªBº) is 119 mm (4.70 in.) (Fig.
12).
(4) With the engine held at the proper position,
tighten both the upper and lower torque strut bolts
to 118 N´m (87 ft. lbs.) (Fig. 10).
(5) Remove the floor jack.
ENGINE MOUNTÐLEFT
REMOVAL
(1) Raise vehicle approximately 30.5 cm (12 in.) on
hoist
(2) Remove air cleaner assembly (Fig. 13).
(3) Remove battery and tray.
(4) Support transaxle with a suitable jack.
(5) Remove left front wheel.
(6) Remove left splash shield.
(7) Remove through bolt access plug at left side
outer frame rail.
Fig. 10 Torque StrutsÐUpper and Lower
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET
3 ± TORQUE STRUT BRACKET
4 ± UPPER TORQUE STRUT5 ± CROSSMEMBER
6 ± LOWER TORQUE STRUT
7 ± BOLTS
8 ± RIGHT FENDER
Fig. 11 Floor Jack Positioning
1 ± WOOD BLOCK
2 ± FLOOR JACK
PL2.0L SOHC ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)

(8) Remove mount through bolt (Fig. 14).
(9) Disconnect transaxle shift cable from left
mount and transaxle linkage.
(10) Remove left mount bracket to body frame rail
fasteners (Fig. 15).
(11) Remove mount attaching bolts (Fig. 16) or
(Fig. 17).
(12) Remove mount.
INSTALLATION
(1) Install mount and attaching bolts (Fig. 16) or
(Fig. 17). Tighten bolts to 68 N´m (50 ft. lbs.).(2) Install engine mount bracket to body frame rail
and tighten fasteners to 28 N´m (250 in. lbs.) (Fig.
15).
(3) Position engine/transaxle for installation of
through bolt. Install and tighten through bolt to 118
N´m (87 ft. lbs.) (Fig. 14).
(4) Remove jack from under transaxle.
(5) Install through bolt access plug at left side
outer frame rail.
(6) Install left splash shield and wheel.
(7) Connect transaxle shift cable to engine mount
and transaxle linkage.
(8) Install battery tray and battery.
Fig. 12 Engine Position Measurement
Fig. 13 Air Cleaner Assembly
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCT
Fig. 14 Left Mount Through Bolt
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
Fig. 15 Left Mount Bracket
1 ± MOUNT BRACKET
2 ± BODY FRAME RAIL
9 - 22 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(4) Discharge air conditioning system, if equipped.
Refer to Group 24, Heating and Air Conditioning for
procedure.
(5) Disconnect the following: air intake duct at
intake manifold, throttle cables, electrical connectors
from throttle body and air cleaner housing.
(6) Remove air cleaner housing assembly.
(7) Remove upper radiator hose and fan module.
Refer to Group 7, Cooling System for procedure.
(8) Remove lower radiator hose.
(9) Disconnect automatic transmission cooler lines
and plug, if equipped.
(10) Disconnect shift linkage, electrical connectors,
and clutch cable, if equipped with manual transaxle.
(11) Disconnect engine wiring harness.
(12) Disconnect positive cable from Power Distri-
bution Center (PDC) and ground wire from vehicle
body.
(13) Disconnect ground wire from the vehicle body-
to-engine at the right side strut tower.
(14) Disconnect heater hoses.
(15) Disconnect vacuum hose from brake booster.
(16) Disconnect coolant reserve/recovery hose.
(17) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(18) Remove power steering pump and reservoir
and set them aside.
(19) Hoist vehicle and remove right inner splash
shield.
(20) Drain engine oil.
(21) Remove front wheels.
(22) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(23) Disconnect exhaust system from manifold.
(24) Disconnect the downstream oxygen sensor
connector.
(25) Remove lower engine torque strut.
(26) Remove structural collar. Refer to procedure
in this section.
(27) Lower vehicle and remove A/C compressor.
(28) Raise vehicle enough to allow engine dolly
and cradle, Special Tools 6135 and 6710 to be
installed under vehicle.
(29) 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. 26). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(30) Install safety straps around the engine to cra-
dle (Fig. 26). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used.(31) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(32) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(33) Remove the upper engine torque strut.
(34) Remove right and left engine and transaxle
mount through bolts (Fig. 24) and (Fig. 25).
(35) Raise vehicle slowly until body is approxi-
mately 15 cm (6 in.) above normal engine mounting
locations.
(36) Remove generator, lower bracket, and upper
mounting bolt.
(37) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary to move the engine/transmission
assembly with the cradle to allow for removal around
body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly until vehicle is within 15
cm (6 in.) of engine mounting locations.
(2) Install generator, lower bracket, and adjusting
bolt.
(3) Continue lowering vehicle until engine/tran-
saxle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 24) and (Fig. 25). Tighten bolts to 118 N´m (87
ft. lbs.).
(4) Install upper engine torque strut. Refer to pro-
cedure in this section.
(5) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(6) Install axle shafts. Refer to Group 3, Differen-
tial and Driveline for procedure.
(7) Install structural collar. Refer to procedure in
this section tightening sequence.
Fig. 24 Right Mount Through Bolt
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
9 - 26 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install lower engine torque strut. Refer to pro-
cedure in this section.
(9) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System for procedure and torque
specifications.
(10) Connect the downstream oxygen sensor.
(11) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(12) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(13) Install inner splash shield.
(14) Install wheels and lower vehicle.
(15) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(16)Manual Transmission:Connect clutch cable,
reverse light electrical connector and shift linkages.
Refer to Group 6, Clutch.
(17)Automatic Transmission:Connect shifter,
kickdown linkage and cooler lines. Refer to Group 21,
Transaxle for procedures.
(18) Connect fuel line and heater hoses.
(19)
Install all ground straps. Connect engine wiring
harness. Refer to Group 8, Electrical for procedure.
(20) Install lower radiator hose, fan module, and
upper radiator hose. Refer to Group 7, Cooling Sys-
tem for procedures
(21) Fill cooling system. Refer to Group 7, Cooling
System for filling procedure.
(22) Install battery tray and battery.
(23) Install air cleaner housing assembly and con-
nect intake duct to intake manifold.(24) Connect all throttle body electrical connectors
and linkage.
(25) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(26) 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.
Fig. 25 Left Mount Through Bolt
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
Fig. 26 Positioning Engine Cradle Support Post
1 ± SAFETY STRAPS
2 ± PLACE REAR POSTS INTO LOCATING HOLES
3 ± SPECIAL TOOL 6848
4 ± SPECIAL TOOL 6710
5 ± SPECIAL TOOL 6135
6 ± SAFETY STRAPS
7 ± PLACE FRONT POST UNDER BLOCK FLANGE
PL2.0L SOHC ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)

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.
(3) Remove power steering/air conditioning drive
belt. Refer to Group 7, Cooling System Accessory
Drive for procedure.
(4) Raise vehicle.
(5) Drain cooling system. Refer to Group 7, Cooling
System.
(6) Remove exhaust pipe from manifold.
(7) Remove right front wheel.
(8) Remove right side splash shield.
(9) Remove generator belt. Refer to Group 7, Cool-
ing System Accessory Drive Belts for procedure.
(10) Remove crankshaft damper. Refer to proce-
dure in this section.
(11) Remove lower torque strut.
(12) Lower vehicle and remove upper torque strut.
(13) Remove ground strap and power steering hose
support clip from engine mount bracket.
(14) Remove power steering pump assembly and
set aside.
(15) Support engine from beneath with a suitable
jack.
(16) Remove right side engine mount to bracket
through bolt.
(17) Remove the lower engine mount bracket bolt.
Raise engine slightly and remove the upper engine
mount bracket bolts.(18) Remove engine mount bracket. This procedure
may require additional raising/lowering of engine
until bracket will clear engine components.
(19) Remove front timing belt cover.
(20) Rotate engine until timing marks are aligned.
(21) Remove timing belt and tensioner. Refer to
procedures in this section.
(22) Remove camshaft sprocket. Refer to proce-
dures in this section.
(23) Remove rear timing belt cover.
(24) Disconnect fuel line at fuel rail.
(25) Remove coolant recovery container.
(26) Remove ground wire to cylinder head.
(27) Remove upper radiator hose.
(28) Remove intake manifold. Refer to procedure
in this section.
(29) Disconnect ignition coil electrical connector.
Remove coil pack and spark plug cables from engine.
(30) Remove Crankcase Closed Ventilation (CCV)
hose from cylinder head cover.
(31) Disconnect cam sensor and coolant tempera-
ture electrical connectors.
(32) Remove heater tube to cylinder head attach-
ing fasteners.
(33) Remove heater hose from thermostat housing
connector.
(34) Remove cylinder head cover.
(35) Remove cylinder head bolts.
(36) Remove cylinder head and gasket (Fig. 55).
PL2.0L SOHC ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

(13) Install ignition coil and spark plug cables.
Connect coil electrical connector.
(14) Install intake manifold. Refer to procedure in
this section.
(15) Install upper radiator hose.
(16) Install ground wire to cylinder head.
(17) Install coolant recovery container.
(18) Connect fuel line to fuel rail.
(19) Install rear timing belt cover, camshaft
sprocket, and timing belt tensioner and timing belt.
Refer to procedures in this section.
(20) Install front timing belt cover.
(21) Install engine mount bracket.
(22) Position engine and install right side engine
mount to engine mount bracket bolt. Tighten bolt to
118 N´m (87 ft. lbs.). Remove jack from beneath
engine.
(23) Install power steering pump assembly.
(24) Install power steering hose support clip and
ground strap to engine mount bracket.
(25) Install upper torque strut.
(26) Raise vehicle.
(27) Install lower torque strut.
(28) Install crankshaft damper.
(29) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Belt for procedure.
(30) Install right side splash shield and front
wheel.
(31) Install exhaust pipe to exhaust manifold
flange.
(32) Lower vehicle and fill cooling system. Refer to
Group 7, Cooling System for procedure.
(33) Connect negative cable to battery.
(34) 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.
CRANKSHAFT DAMPER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(2) Raise vehicle on a hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 61).
INSTALLATION
(1) Install crankshaft damper using M12±1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792 (Fig. 62).
Fig. 62 Crankshaft DamperÐInstallation
1 ± M12 Ð 1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
Fig. 60 Cylinder Head Tightening Sequence
Fig. 61 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 6827±A INSERT
2 ± SPECIAL TOOL 1026 THREE JAW PULLER
9 - 40 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT
REMOVAL
(1) Remove engine assembly. Refer to procedure in
this section.
(2) Remove structural collar from oil pan to tran-
saxle housing.
(3) Separate transaxle from engine.
(4) Remove drive plate/flywheel.
(5) Remove crankshaft rear oil seal. Refer to pro-
cedure in this section.
(6) Mount engine on a suitable repair stand.
(7) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(8) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(9) Remove crankshaft sprocket. Refer to proce-
dure in this section.(10) Remove lower torque strut/air conditioning
compressor mounting bracket from engine (Fig. 95).
(11) Remove oil filter and adapter.
(12) Remove oil pan.
(13) Remove oil pump pick-up tube.
(14) Remove oil pump.
(15) Remove crankshaft position sensor.
(16) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(17) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
Fig. 94 Crankshaft and Components
1 ± OIL PASSAGE O-RING
2 ± SEAL
3 ± UPPER BEARING (GROOVED)
4 ± THRUST BEARINGS
5 ± BOLT
6 ± O-RING
7 ± NIPPLE8 ± OIL FILTER ADAPTER
9 ± CRANKSHAFT POSITION SENSOR (CPS)
10 ± MAIN BEARING CAP/BED PLATE ASSEMBLY
11 ± CONNECTING ROD BEARINGS
12 ± PISTON AND CONNECTING ROD ASSEMBLY
13 ± SEAL
9 - 52 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(17) Install rear timing belt cover and camshaft
sprocket.
(18) Install crankshaft sprocket, timing belt ten-
sioner, timing belt, and cover.
(19) Install front engine mount bracket.
(20) Remove engine from repair stand and position
on Special Tools 6135 and 6710 Engine Dolly and
Cradle. Install safety straps around the engine to
cradle and tighten and lock them into position.
(21) Install crankshaft rear oil seal. Refer to proce-
dure in this section.
(22) Install drive plate/flywheel. Apply Mopart
Lock & Seal Adhesive to bolt threads and tighten to
95 N´m (70 ft. lbs.).
(23) Install transaxle to engine.
(24) Install structural collar. Refer to procedure in
this section.
(25) Install engine assembly. Refer to procedure in
this section.
(26) 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. 101).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 102),
avoid deforming the filter. Use an appropriate oil fil-
ter removing tool. Position filter wrench strap close
the seam at the base of the filter. The oil filter seam
that joins the can to the base, is reinforced by the
base plate.
(1) Turn filter counterclockwise to remove.
(2) Clean and check the filter mounting surface.
The surface must be smooth, flat and free of debris
or old pieces of rubber.
(3) To install, lubricate new filter gasket. Screw fil-
ter on until gasket contacts base. Tighten to 21 N´m
(15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(3) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(4) Remove oil pan. Refer to procedure in this sec-
tion.
(5) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 103).
(6) Remove oil pick-up tube.
(7) Remove oil pump (Fig. 104) and front crank-
shaft seal.
Fig. 101 Engine Oil Filter Adapter to Engine Block
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 102 Engine Oil Filter
1 ± OIL FILTER
2 ± DRAIN PLUG
PL2.0L SOHC ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)