TIMING DODGE NEON 2000 Service Owner's Manual

(2) Install crankshaft damper bolt. Using Special
Tool 6847 and a torque wrench, tighten bolt to 136
N´m (100 ft. lbs.) (Fig. 63).
(3) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(4) Raise vehicle on hoist and install right inner
splash shield.
TIMING BELT COVERS
FRONT TIMING BELT COVER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(2) Remove crankshaft damper. Refer to procedure
in this section.
(3) Remove lower and upper torque struts. Refer to
procedure in this section.
(4) Position a jack under engine. Raise jack
enough to support engine weight.
(5) Remove right engine mount to engine mount
bracket bolt.
(6) Remove power steering pump assembly and set
aside.
(7) Remove right engine mount bracket.
(8) Remove front timing belt cover (Fig. 64).INSTALLATION
(1) Install front timing belt cover and tighten bolts
to 12 N´m (105 in. lbs.).
(2) Install front engine mount bracket.
(3) Install right side engine mount to engine
mount bracket bolt.
(4) Remove jack from under engine.
(5) Install power steering pump assembly.
(6) Install upper and lower engine torque struts.
Refer to procedure in this section.
(7) Install crankshaft damper. Refer to procedure
in this section.
(8) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.REAR TIMING BELT COVER
REMOVAL
(1) Remove front timing belt cover following proce-
dure in this section.
(2) Remove timing belt and timing belt tensioner.
Refer to procedures in this section.
(3) Hold camshaft sprocket with Special Tools
C-4687 and modified Adaptor C-4687-1 (Fig. 66),
while removing attaching bolt.
(4) Remove camshaft sprocket.
(5) Remove rear timing cover attaching bolts (Fig.
65).
(6) Remove rear timing cover (Fig. 65).
Fig. 63 Crankshaft Damper Bolt Tightening
1 ± SPECIAL TOOL 6847
2 ± CRANKSHAFT DAMPER
Fig. 64 Front Timing Belt Cover
1 ± ACCESS PLUG
2 ± BOLTS
PL2.0L SOHC ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install rear timing cover and tighten bolts to
12 N´m (105 in. lbs.) (Fig. 65).
(2) Install camshaft sprocket. While holding
sprockets with Special Tools C-4687 and modifiedAdaptor C-4687-1, tighten attaching bolt to 101 N´m
(75 ft. lbs.).
(3) Install timing belt tensioner assembly and tim-
ing belt. Refer to procedure in this section.
(4) Install front timing belt cover following proce-
dure in this section.
Fig. 65 Rear Timing Belt Cover
1 ± BOLTS
Fig. 66 Modification to Special Tool C-4687-1
1 ± GRIND LOCATION
2 ± 12.7 MM (1/2 IN.)
3 ± 50.8 MM (2 IN.)
9 - 42 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

TIMING BELT
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. 67).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 68).
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.(3) Remove crankshaft damper bolt. Remove
damper using Special Tools 1026 three jaw puller
and 6827-A insert (Fig. 69).
(4) Remove lower torque strut.
(5) Lower vehicle and place a jack under engine.
(6) Remove upper torque strut.
(7) Remove right engine mount to engine mount
bracket through bolt.
(8) Remove power steering pump assembly and set
aside.
(9) Remove engine mount bracket (Fig. 70).
(10) Remove front timing belt cover (Fig. 71).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft.
Fig. 67 Timing Belt System
1 ± CAMSHAFT SPROCKET
2 ± REAR TIMING BELT COVER
3 ± TIMING BELT TENSIONER ASSEMBLY
4 ± WATER PUMP
5 ± OIL PUMP BODY
6 ± CRANKSHAFT SPROCKET7 ± TIMING BELT
8 ± BOLT
9 ± CRANKSHAFT DAMPER
10 ± FRONT TIMING BELT COVER
11 ± ACCESS PLUG
12 ± CAMSHAFT BOLT AND WASHER
PL2.0L SOHC ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)

(11) Inserta8mmAllen wrench into the hexagon
opening located on the front of the belt tensioner pul-
ley (Fig. 72). Rotate the pulley counterclockwise until
it contacts the stop. While holding tensioner pulley
against stop, insert a 1/8º or 3 mm diameter pin or
Allen wrench through the hole located to the left of
the hex opening (Fig. 72). While pushing pin into
hole, allow the tensioner pulley to rotate back.
Almost immediately, the pin should engage the lock-
ing hole to prevent further movement of the pulley.
(12) Remove timing belt.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
Fig. 68 Camshaft Timing Marks
1 ± CAM SPROCKET TIMING MARK
2 ± ARROW ON REAR COVER
Fig. 69 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 6827±A INSERT
2 ± SPECIAL TOOL 1026 THREE JAW PULLER
Fig. 70 Right Engine Mount Bracket
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET ASSEMBLY
Fig. 71 Timing Belt Cover
1 ± ACCESS PLUG
2 ± BOLTS
9 - 44 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
(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. 73).(2) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 73).
(3) Move crankshaft to 1/2 mark before TDC (Fig.
75) 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. 76).
(8) Install front timing belt cover.
(9) Install engine mount bracket.
Fig. 72 Timing Belt Removal
1 ± CAMSHAFT TIMING MARKS
2 ± BELT TENSIONER
3 ± CRANKSHAFT AT TDC
4 ± 1/8º OR 3mm ALLEN WRENCH
5 ± 8 mm ALLEN WRENCH
Fig. 73 Crankshaft Sprocket Timing
1 ± TDC MARK
Fig. 74 Camshaft Timing Mark
1 ± CAM SPROCKET TIMING MARK
2 ± ARROW ON REAR COVER
Fig. 75 Adjusting Crankshaft Sprocket for Timing
Belt Installation
1 ± TDC REFERENCE MARK
2 ± 1/2 NOTCH LOCATION
3 ± TDC MARK
PL2.0L SOHC ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)

(10) Install right engine mount to engine mount
bracket through bolt.
(11) Remove jack from under engine.
(12) Install upper torque strut.
(13) Install power steering pump assembly.
(14) Raise vehicle and install lower torque strut.
(15) 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 (100 ft. lbs.) (Fig. 77).
(16) Install accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(17) Install right inner splash shield.
(18) 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
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 TENSIONER
REMOVAL
(1) Remove timing belt. Refer to procedure in this
section.
(2) Remove tensioner assembly attaching bolts
(Fig. 78).
(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 31 N´m (275 in. lbs.).
(2) Install timing belt. Refer to procedure in this
section.
CAMSHAFT OIL SEAL
REMOVAL
CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.
(1) Remove crankshaft damper, front timing belt
cover, timing belt and tensioner assembly. Refer to
procedures in this section.
(2) Hold camshaft sprocket with Special Tools
C-4687 and modified C-4687-1 as shown in (Fig. 79),
while removing attaching bolt.
(3) Remove sprocket from camshaft.
(4) Remove rear timing belt cover.
Fig. 76 Crankshaft and Camshaft Timing
1 ± CAMSHAFT TIMING MARKS
2 ± CRANKSHAFT AT TDC
Fig. 77 Crankshaft DamperÐInstallation
1 ± M12 Ð 1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
9 - 46 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Remove camshaft seal by carefully using a suit-
able pry tool. Be careful not to nick or damage thecamshaft seal surface or cylinder head seal retaining
bore.
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper, if necessary.
INSTALLATION
(1) Install camshaft seal flush with cylinder head
using Special Tool MD998306 (Fig. 80).
(2) Install rear timing belt cover.
(3) Install camshaft sprocket retaining bolt. Hold
camshaft sprocket with Special Tools C-4687 and
modified C-4687-1 (Fig. 79) and tighten bolt to 115
N´m (85 ft. lbs.).
(4) Install timing belt tensioner, timing belt, front
cover, and crankshaft damper. Refer to procedures in
this section.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Drain engine oil and remove oil filter.
(4) Remove oil filter adaptor from engine block
(Fig. 81).
(5) Remove structural collar. Refer to procedure in
this section.
(6) Remove lateral bending brace attaching bolts
(Fig. 82).
(7) Remove lateral bending brace (Fig. 82).
(8) Remove transaxle dust cover (Fig. 82).
(9) Remove oil pan bolts.
(10) Remove oil pan.
INSTALLATION
(1) Clean oil pan and all sealing surfaces.
Fig. 78 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 ± TIMING BELT TENSIONER ASSEMBLY
2 ± TENSIONER ASSEMBLY ATTACHING BOLTS
Fig. 79 Modification to Special Tool
1 ± GRIND LOCATION
2 ± 12.7 MM (1/2 IN.)
3 ± 50.8 MM (2 IN.)
Fig. 80 Camshaft Oil SealÐInstallation
1 ± SPECIAL TOOL MD 998306
PL2.0L SOHC ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

(2) Apply MopartSilicone Rubber Adhesive Seal-
ant at the oil pump to engine block parting line (Fig.
83).
(3) Position a new oil pan gasket onto pan.
(4) Install oil pan and tighten screws to 12 N´m
(105 in. lbs.).
(5) Install transaxle dust cover (Fig. 82).
(6) Install lateral bending brace (Fig. 82).(7) Install structural collar. Refer to procedure in
this section.
(8) Install oil filter adaptor and tighten assembly
to 80 N´m (60 ft. lbs.) (Fig. 81).
(9) Install oil filter.
(10) Lower vehicle and fill engine crankcase with
proper oil to correct level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(2) Remove crankshaft damper. Refer to procedure
in this section.
(3) Remove front timing belt cover and timing belt.
Refer to procedures in this section.
(4) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 84).
(5) Remove crankshaft sprocket key from crank-
shaft (Fig. 85).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 81 Oil Filter Adaptor
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 82 Bending Brace, Structural Collar, and Dust
Cover
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 83 Oil Pan Sealing
1 ± PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING
LINE OF THE OIL PUMP TO ENGINE BLOCK
Fig. 84 Crankshaft SprocketÐRemoval
1 ± SPECIAL TOOL 6793
2 ± SPECIAL TOOL C-4685-C2
3 ± CRANKSHAFT SPROCKET
9 - 48 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(6) Using Special Tool 6771, remove front crank-
shaft oil seal (Fig. 86). Do not damage the seal con-
tact area on the crankshaft.
INSTALLATION
(1) Position seal into opening with seal spring
towards the inside of engine. Using Special Tool
6780-1 (Fig. 87), install seal until flush with cover.
(2) Install crankshaft sprocket key (Fig. 85).
(3) Install crankshaft sprocket (Fig. 88) using Spe-
cial Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing outward.NOTE: Use of Special Tool 6792 is required to set
proper crankshaft sprocket depth for proper timing
belt tracking.
Fig. 85 Crankshaft Key
1 ± CRANKSHAFT KEY
Fig. 86 Front Crankshaft Oil SealÐRemoval
1 ± SPECIAL TOOL 6771
Fig. 87 Front Crankshaft Oil SealÐInstallation
1 ± PROTECTOR
2 ± SEAL
3 ± SPECIAL TOOL 6780±1
4 ± INSTALLER
Fig. 88 Crankshaft SprocketÐInstallation
1 ± SPECIAL TOOL 6792
PL2.0L SOHC ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)

(4) Install timing belt and cover. Refer to proce-
dures in this section.
(5) Install crankshaft damper. Refer to procedure
in this section.
(6) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
CRANKSHAFT OIL SEALÐREAR
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove drive plate. Refer to procedure in this
section.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 89) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 90).
(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 90).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 91) until the tool bot-
toms out against the block (Fig. 92).
(4) Install drive plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install transaxle. Refer to Group 21, Transaxle
for procedure.
Fig. 89 Rear Crankshaft Oil SealÐRemoval
1 ± REAR CRANKSHAFT SEAL
2 ± ENGINE BLOCK
3 ± ENGINE BLOCK
4 ± REAR CRANKSHAFT SEAL METAL CASE
5 ± PRY IN THIS DIRECTION
6 ± CRANKSHAFT
7 ± SCREWDRIVER
8 ± REAR CRANKSHAFT SEAL DUST LIP
9 ± SCREWDRIVERFig. 90 Rear Crankshaft Seal and Special Tool
6926-1
1 ± SPECIAL TOOL 6926±1 PILOT
2 ± SEAL
9 - 50 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)