lock DODGE NEON 2000 Service Repair Manual

(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)

(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)

NOTE: Do not reuse connecting rod bolts.
(18) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 96).
(19) Using a mallet tap the bedplate loose from the
engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.
(20) Bedplate should be removed evenly from the
cylinder block dowel pins.
(21) Lift out crankshaft from cylinder block (Fig.
94). Be sure not to damage the main bearings or
journals when removing the crankshaft.
CRANKSHAFT MAIN BEARINGS LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves. All lower bearing shells installed in the (bed-
plate) main bearing cap are plain. Crankshaft endplay is controlled by a flanged bearing on the number
three main bearing journal (Fig. 97).
NOTE: The upper and lower main Bearing shells
are Not interchangeable. The lower shells have a
revised tab to prevent improper installation.
CRANKSHAFT MAIN JOURNALS INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.025 mm (0.001 in.). Journal grinding should
not exceed 0.305 mm (0.012 in.) under the standard
journal diameter. DO NOT grind thrust faces of
Number 3 main bearing. DO NOT nick crank pin or
bearing fillets. After grinding, remove rough edges
from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 97). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.016 mm
(0.0006 in.), 0.032 mm (0.0012 in.), 0.250 mm (0.010
in.). Never install an undersize bearing that will
reduce clearance below specifications.
Fig. 95 Torque Strut Bracket
1 ± BOLTS
2 ± TORQUE STRUT BRACKET
Fig. 96 Bedplate Bolts
Fig. 97 Main Bearing Identification
1 ± OIL GROOVES
2 ± UPPER BEARINGS
3 ± LOWER BEARINGS
4 ± OIL HOLES
PL2.0L SOHC ENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block. Install O-ring
into recess in the block (Fig. 98).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do Not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft in cylinder block.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5±2.0 mm (0.059±0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 99).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts oil threads with
clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block (Fig. 100).(8) Install main bearing bedplate to engine block
bolts (1±10) and torque each bolt to 81 N´m (60 ft.
lbs.) in sequence shown in (Fig. 100).
(9) Install main bearing bedplate to engine block
bolts (11±20), with baffle studs in positions 12, 13
and 16 and torque each bolt to 34 N´m (25 ft. lbs.) in
sequence shown in (Fig. 100).
(10) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(11) If crankshaft end play is to be checked, refer
to service procedures in this section.
(12) Install connecting rod bearings and caps.
Install new connecting rod bolts and tighten to 27
N´m (20 ft. lbs.) plus 1/4 turn.
(13) Install oil pump and crankshaft front oil seal.
(14) Install oil pick-up tube and oil pan. Refer to
procedure in the section.
(15) Install oil filter adapter and filter.
(16) Install lower torque strut/air conditioning
compressor mounting bracket to engine (Fig. 95).
Fig. 98 Installing Main Bearing Upper Shell
1 ± LUBRICATION GROOVES
2 ± O-RING
3 ± OIL HOLES
Fig. 99 Main Bearing Caps/Bedplate Sealing
Fig. 100 Main Bearing Caps/Bedplate Torque
Sequence
9 - 54 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)

INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 105). Install oil ring into oil pump
body discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N´m
(250 in. lbs.).
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 106).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 107).
Fig. 104 Oil Pump and Tube
1 ± O-RING
2 ± OIL FILTER ADAPTER
3 ± OIL PAN GASKET
4 ± OIL PAN
5 ± OIL PICK-UP TUBE
6 ± DRAIN PLUG7 ± O-RING
8 ± OIL PUMP BODY
9 ± FILTER
10 ± O-RING
11 ± NIPPLE
Fig. 103 Crankshaft SprocketÐRemoval
1 ± SPECIAL TOOL 6793
2 ± SPECIAL TOOL C-4685-C2
3 ± CRANKSHAFT SPROCKET
9 - 56 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install oil pick-up tube and oil pan.
(9) Install rear timing belt cover and camshaft
sprocket.
(10) Install timing belt tensioner, timing belt, and
front timing belt cover.
(11) Install crankshaft damper.
(12) Fill engine crankcase with proper oil to cor-
rect level.
(13) Connect negative cable to battery.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove cylinder head and oil pan. Refer to pro-
cedures in this section.
(2) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 108).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(3) Using a permanent ink marker or scribe tool
mark the cylinder number on the side of the rod and
cap (Fig. 109) for identification.
Fig. 105 Oil Pump Sealing
1 ± APPLY GASKET MAKER TO OIL PUMP BODY FLANGE
2 ± O-RING
Fig. 106 Front Crankshaft SealÐInstallation
1 ± PROTECTOR
2 ± SEAL
3 ± SPECIAL TOOL 6780±1
4 ± INSTALLER
Fig. 107 Crankshaft SprocketÐInstallation
1 ± SPECIAL TOOL 6792
2 ± TIGHTEN NUT TO INSTALL
Fig. 108 Piston Markings
1 ± WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL
BE IMPRINTED IN THIS AREA
PL2.0L SOHC ENGINE 9 - 57
REMOVAL AND INSTALLATION (Continued)

(4) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 108). These stamps will
be either a directional arrow or a weight identifica-
tion for the assembly. L is for light and H is for
heavy. These assemblies should all be the same
weight class. Service piston assemblies are marked
with a S and can be used with either L or H produc-
tion assemblies. The weight designation stamps
should face toward the timing belt side of the engine.
(5) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(6) Remove connecting rod cap bolts.Do not use
old bolts if reinstalling connecting rod.
(7) To protect crankshaft journal and fractured rod
surfaces, install Special Tool 8189, connecting rod
guides onto connecting rod (Fig. 110). Carefully push
each piston and rod assembly out of cylinder bore.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint surfaces, as engine
damage many occur.
(8) Remove Special Tool 8189, connecting rod
guides and re-install bearing cap on the mating rod.
NOTE: Piston and rods are serviced as an assem-
bly.
PISTON RINGÐREMOVAL
(1) The identification mark on face of upper and
intermediate piston rings must point toward piston
crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 111).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.
PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers identification
mark facing up, to the top of the piston (Fig. 112).CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
f. Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position.Do not use a piston
ring expander (Fig. 113).
(2) Install upper side rail first and then the lower
side rail.
(3) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 112).
(4) Position piston ring end gaps as shown in (Fig.
114).
Fig. 109 Identify Connecting Rod to Cylinder
Fig. 110 Connecting Rod GuidesÐTypical
1 ± SPECIAL TOOL 8189 CONNECTING ROD GUIDES
Fig. 111 Piston RingsÐRemoving and Installing
9 - 58 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)