tra DODGE NEON 2000 Service Repair Manual

(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)

DRIVE PLATE
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove drive plate attaching bolts (Fig. 93).
(3) Remove drive plate (Fig. 93).
INSTALLATION
(1) Position drive plate on crankshaft (Fig. 93).
(2) Apply MopartLock & Seal Adhesive to drive
plate bolt threads.
(3) Install drive plate bolts and tighten to 95 N´m
(70 ft. lbs.) (Fig. 93).
(4) Install transaxle. Refer to Group 21, Transaxle
for procedure.
Fig. 91 Crankshaft Seal Special Tool 6926-2
1 ± SPECIAL TOOL 6926±1 PILOT
2 ± SEAL
3 ± SPECIAL TOOL 6926±2 INSTALLER
Fig. 92 Rear Crankshaft SealÐInstallation
1 ± SPECIAL TOOL 6926±2 INSTALLER
Fig. 93 Drive Plate
1 ± ADAPTOR PLATE
2 ± BOLT
3 ± BOLT (QTY. 8)
4 ± DRIVE PLATE
PL2.0L SOHC ENGINE 9 - 51
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)

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.
(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±1.25 mm
(0.030±0.049 in.) (Fig. 122).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip until within specifications. Measure from valve
tip to spring seat when installed in the head (mea-
surement A) (Fig. 123). For specifications, refer to
Engine Specifications in this section. 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. 124). 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.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height after
refacing the valve and seat (measurment B) (Fig.
123). Make sure measurements are taken from top of
spring seat to the bottom surface of spring retainer.
If height is greater than 40.18 mm (1.58 in.), install
Fig. 122 Valve Seat Refacing
Fig. 123 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
1 ± GARTER SPRING
2 ± VALVE SPRING SEAT
3 ± CYLINDER HEAD SURFACE
Fig. 124 Valve Stem Oil Seal Tool
1 ± VALVE SEAL TOOL
2 ± VALVE STEM
9 - 62 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

a 0.762 mm (0.030 in.) spacer under the valve spring
seat to bring spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster(s) to bleed down before rotating
cam.
CLEANING AND INSPECTION
INTAKE MANIFOLD
CLEAN AND INSPECT
Check for:
²Inspect manifold for cracks or distortions.
²Check for torn or missing O-rings at the mating
surface of the manifold (Fig. 125).
EXHAUST MANIFOLD
CLEAN AND INSPECT
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head.
(2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion.
Replace manifold if necessary.
CYLINDER HEAD AND CAMSHAFT JOURNALS
CLEANING
Remove all gasket material from cylinder head. Be
careful not to gouge or scratch the aluminum head
sealing surface. Clean all engine oil passages.
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean aluminum gasket
surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 126)
NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 126)
²Drill motor with 3M RolocyBristle Disc (white
or yellow) (Fig. 126)
CAUTION: Excessive pressure or high RPM can
damage the sealing surfaces. The mild (white, 120
grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
on cast iron surfaces with care.
Fig. 125 Intake Manifold O-Rings
1 ± INTAKE MANIFOLD O-RING GASKETS
Fig. 126 Proper Tool Usage For Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
PL2.0L SOHC ENGINE 9 - 63
DISASSEMBLY AND ASSEMBLY (Continued)

INSPECTING CYLINDER HEAD
Check cylinder head for flatness with a straight
edge. Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 127).
INSPECTING CAMSHAFT JOURNALS
Inspect cylinder head camshaft bearings for wear.
Check the camshaft journals for scratches and worn
areas. If light scratches are present, they may be
removed with 400 grit sand paper. If deep scratches
are present, replace the camshaft and check the cyl-
inder head for damage. Replace the cylinder head if
worn or damaged. Check the lobes for pitting and
wear. If the lobes show signs of wear, check the cor-
responding rocker arm roller for wear or damage.
Replace rocker arm/hydraulic lash adjuster if worn or
damaged. If lobes show signs of pitting on the nose,
flank or base circle; replace the camshaft.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of
the oil pump should be smooth. Replace pump cover
if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 128). If a 0.076 mm (0.003 inch.) feeler
gauge can be inserted between cover and straight
edge, cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301
inch.) or less (Fig. 129), or if the diameter is 79.95
mm (3.148 inches) or less, replace outer rotor.
(4) If inner rotor measures 7.64 mm (0.301 inch) or
less replace inner rotor (Fig. 130).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 131). If measurement is 0.39
Fig. 127 Checking Cylinder Head Flatness
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
Fig. 128 Checking Oil Pump Cover Flatness
1 ± OIL PUMP BODY
2 ± OIL PUMP COVER
3 ± OUTER ROTOR
4 ± INNER ROTOR
Fig. 129 Measuring Outer Rotor Thickness
Fig. 130 Measuring Inner Rotor Thickness
9 - 64 2.0L SOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
(6) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 132) is
0.203 mm (0.008 inch) or more, replace both rotors.(7) Place a straightedge across the face of the
pump housing, between bolt holes. If a feeler gauge
of 0.102 mm (0.004 inch) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 133).ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 60.7 mm (2.39 inches) it should test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 inches). Replace spring that fails to meet
specifications.
(10) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings, damaged
or missing oil pick-up tube O-ring, clogged oil pick-up
tube screen, clogged oil filter and stuck open pres-
sure relief valve or other reasons for oil pressure
loss.
CYLINDER BLOCK AND BORE
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Engine
Core Plugs in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
Fig. 131 Measuring Outer Rotor Clearance in
Housing
1 ± FEELER GAUGE
2 ± OUTER ROTOR
Fig. 132 Measuring Clearance Between Rotors
1 ± FEELER GAUGE
2 ± INNER ROTOR
3 ± OUTER ROTOR
Fig. 133 Measuring Clearance Over Rotors
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
PL2.0L SOHC ENGINE 9 - 65
CLEANING AND INSPECTION (Continued)