lock DODGE NEON 2000 Service Repair Manual

(10) Install connecting rod lower bearing half and
cap. InstallNewbolts and tighten to 27 N´m (20 ft.
lbs.) plus 1/4 turn.
(11) Install cylinder head and oil pan. Refer to pro-
cedures in this section.
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. 116).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 116) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 116).
(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. 117).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B with Adaptor
6526.(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
(0.002 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. 118). Replace guides if they are not within
specification. For specifications, refer to Engine Spec-
ifications in this section.
(3) Check valve guide height (Fig. 119).
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
33.34 mm (1-5/16 in.). Turn tool table until surface is
in line with the 33.34 mm (1-5/16 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device (Fig. 120). Pull on torque
Fig. 116 Oil Pressure Relief Valve
1 ± RETAINER CAP
2 ± GASKET
3 ± OIL PUMP BODY
4 ± RELIEF VALVE
5 ± SPRING
Fig. 117 Oil Pump
1 ± OIL PUMP BODY
2 ± OIL PUMP COVER
3 ± OUTER ROTOR
4 ± INNER ROTOR
9 - 60 2.0L SOHC ENGINEPL
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)

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)

CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 134). If the cyl-
inder walls are badly scuffed or scored, the cylinder
block should be rebored and honed, and new pistons
and rings fitted. Whatever type of boring equipment
is used, boring and honing operation should be
closely coordinated with the fitting of pistons and
rings in order that specified clearances may be main-
tained.Refer to Honing Cylinder Bores outlined
in the Standard Service Procedures for specifi-
cation and procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 134). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
For specifications, refer to Engine Specifications in
this section.
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
The upper and lower torque struts need to be
adjusted together to assure proper engine positioning
and engine mount loading. Whenever a torque strut
bolt(s) is loosened, this procedure must be performed.
(1) Loosen the upper and lower torque strut
attaching bolt at the suspension crossmember and
shock tower bracket (Fig. 135).
(2) The engine position may now be adjusted by
positioning a suitable floor jack on the forward edge
of the transmission bell housing (Fig. 136).
NOTE: The floor jack must be positioned as shown
in (Fig. 136) to prevent minimal upward lifting of the
engine.(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.
137).
(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. 135).
(5) Remove the floor jack.
Fig. 134 Checking Cylinder Bore Size
9 - 66 2.0L SOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

Fig. 135 Torque Strut Bolts
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. 136 Floor Jack Positioning
1 ± WOOD BLOCK
2 ± FLOOR JACK
Fig. 137 Engine Position Measurement
PL2.0L SOHC ENGINE 9 - 67
ADJUSTMENTS (Continued)

SPECIFICATIONS
2.0L SOHC ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, SOHC
Number of Cylinders 4
Displacement 2.0 Liters
(122 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 83.0 mm
(3.268 in.)
Compression Ratio 9.8:1
Firing Order 1-3-4-2
Compression Pressure 1172±1551 kPa
(170±225 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons (Federal Emission)
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance 17.5 mm
(11/16 in.) from bottom of
skirt0.012±0.044 mm
(0.0004±0.0017 in.)
Weight 325±335 grams
(11.47±11.82 oz.)
Land Clearance
(Diametrical)0.734±0.797 mm
(0.029±0.031 in.)
Piston Length 64 mm
(2.520 in.)
Piston Ring Groove
Depth No. 13.989±4.188 mm
(0.157±0.165 in.)
Piston Ring Groove
Depth No. 24.462±4.661 mm
(0.176±0.184 in.)
DESCRIPTION SPECIFICATION
Piston Ring Groove
Depth No. 33.847±4.131 mm
(0.151±0.163 in.)
Pistons (Low Emission VehicleÐLEV/ULEV)
Piston Diameter 87.456±87.474 mm
(3.4432±3.4439 in.)
Clearance 10.42 mm
(0.42 in.) from bottom of
skirt0.018±0.50 mm
(0.0008±0.0020 in.)
Weight 320±329 grams
(11.29±11.60 oz.)
Land Clearance
(Diametrical)0.758±0.790 mm
(0.0299±0.0312 in.)
Piston Length 55.8 mm
(2.197 in.)
Piston Ring Groove
Depth No. 13.989±4.188 mm
(0.157±0.165 in.)
Piston Ring Groove
Depth No. 24.462±4.661 mm
(0.176±0.184 in.)
Piston Ring Groove
Depth No. 33.847±4.131 mm
(0.151±0.163 in.)
Piston Pins
Clearance in Piston 0.008±0.015 mm
(0.0003±0.0006 in.)
Clearance in Connecting
RodInterference
Diameter 21.000±21.003 mm
(0.8268±0.8269 in.)
End Play None
Length 74.75±75.25 mm
(2.943±2.963 in.)
Piston Rings
Ring GapÐTop
Compression Ring0.23±0.52 mm
(0.009±0.020 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐ2nd
Compression Ring0.49±0.78 mm
(0.019±0.031 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring GapÐOil Control
Steel Rails0.23±0.66 mm
(0.009±0.026 in.)
9 - 68 2.0L SOHC ENGINEPL

DESCRIPTION SPECIFICATION
Exhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25 mm
(0.010 in.)
Exhaust 0.0736±0.094 mm
(0.0029±0.0037 in.)
Max. Allowable 0.101 mm
(0.004 in.)
Service Limit 0.25 mm
(0.010 in.)
Valve Springs
Free Length (Approx.) 46.75 mm
(1.84 in.)
Nominal Force (Valve
Closed)331 N @ 39.8 mm
(70 lbs. @ 1.57 in.)
Nominal Force (Valve
Open)711 N @ 32.6 mm
(160 lbs. @ 1.28 in.)
Installed Height 40.18 mm
(1.580 in.)
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Camshaft Sensor
Pick-upÐBolts9.6 Ð 85
Camshaft SprocketÐBolt 115 85 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20 +
1¤4
turnÐ
Structural CollarÐBolts Refer to Procedure
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 34 25 Ð
ÐM11 Bolts 81 60 Ð
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts Refer to Procedure
Cylinder Head CoverÐ
Bolts12 Ð 105
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Drive Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine Mounting Refer to Procedure
Exhaust Manifold to
Cylinder HeadÐBolts23 Ð 200
Exhaust Manifold Support
Bracket (Federal and
LEV)
ÐM8 Nut 28 Ð 250
ÐM10 Bolt 54 40 Ð
ÐM12 Bolt 95 70 Ð
Exhaust Manifold Support
Bracket (ULEV)54 40 Ð
Engine Torque Strut
Bracket to EngineÐBolts61 45 Ð
Powertrain Bending
StrutÐFront
ÐLong Bolts 101 75 Ð
ÐShort Bolts 61 45 Ð
Intake ManifoldÐBolts 12 Ð 105
Oil Filter Adaptor 80 60 Ð
Oil Filter 20 15 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump to Block 28 Ð 250
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Pump Relief
ValveÐCap41 30 Ð
PCV Valve 5.6 Ð 50
Rocker Arm ShaftÐBolts 28 Ð 250
Spark Plugs 28 Ð 250
Timing Belt CoverÐBolts 12 Ð 105
Timing Belt Tensioner
AssemblyÐBolts28 Ð 250
Water PumpÐBolts 12 Ð 105
PL2.0L SOHC ENGINE 9 - 71
SPECIFICATIONS (Continued)

CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.*
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(4) Connect the exhaust system ground strap.
Fig. 7 Catalytic Converter, Intermediate Pipe, and Muffler
1 ± CATALYTIC CONVERTER
2 ± INTERMEDIATE PIPE3 ± MUFFLER
4 ± ISOLATORS
* To replace the band clamp; remove the nut and
peel back the ends of the clamp until spot weld
breaks.
Fig. 8 Band Clamp
1 ± CLAMP SIZE
2 ± TORQUE SPECIFICATION
PLEXHAUST SYSTEM 11 - 5
REMOVAL AND INSTALLATION (Continued)

(2) Install exhaust manifold support bracket (Fed-
eral and LEV only). Tighten M10 bolt to 54 N´m (40
ft. lbs.), M12 bolt to 95 N´m (70 ft. lbs.), and nut to
28 N´m (250 in. lbs.).
(3) Install bolt attaching manifold support bracket
to the heat shield (Federal and LEV only). Tighten
bolt to 28 N´m (250 in. lbs.).
(4) Assemble muffler and exhaust pipe to catalytic
converter. Install muffler and pipe support isolators
to the underbody.
(5) Tighten the catalytic converter to exhaust man-
ifold fasteners to 28 N´m (250 in. lbs.) (Fig. 11) or
(Fig. 12).
(6) Working from the front of the systemÐalign
each component to maintain position and proper
clearance with under body components. Tighten all
slip joint band clamps to 47 N´m (35 ft. lbs.).
CAUTION: Band (Torca) clamps should never be
tightened such that the two sides of the clamps are
bottomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
clamping force and must be replaced.
(7) If removed, install downstream oxygen sensor.
(8) Connect downstream oxygen sensor electrical
connector.
CLEANING AND INSPECTION
EXHAUST SYSTEM
Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.
ADJUSTMENTS
EXHAUST SYSTEM ALIGNMENT
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken or loose clamps, heat
shields, insulators, and brackets. Replace or tighten
as necessary. It is important that exhaust system
clearances and alignment be maintained.
Perform the following procedures to align the
exhaust system. Refer to (Fig. 9) for clearance speci-
fications:
(1) Loosen clamps and support brackets.
(2) Align the exhaust system starting at the front,
working rearward.
(3) Tighten all clamps and brackets once align-
ment and clearances are achieved.
SPECIFICATIONS
TORQUE SPECIFICATION CHART
Fig. 12 Catalytic Converter to Exhaust Manifold
ConnectionÐULEV
1 ± PRESSED-IN NUTS
2 ± GASKET
3 ± BOLTS
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Band ClampsÐFastener 47 35 Ð
Catalytic Converter to Exhaust
Manifold FlangeÐFasteners28 Ð 250
11 - 8 EXHAUST SYSTEMPL
REMOVAL AND INSTALLATION (Continued)