torque strut DODGE NEON 2000 Service Owner's Guide

(4) Remove the thermowrap from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BATTERY TRAY
REMOVAL
(1) Remove battery. Refer to Battery Removal and
Installation in this section.
(2) Remove two nuts to the rear and two bolts to
the front of the battery tray (Fig. 18).
(3) Slide battery tray out form under the air
cleaner assembly. Do not remove the air cleaner
assembly.
(4) Remove battery tray from vehicle.
INSTALLATION
For installation reverse the above procedures.
SPECIFICATIONS
BATTERY SPECIFICATIONS
COLD CRANK RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
±18É C (0É F).
RESERVE CAPACITY RATING
The length of time a battery can deliver 25 amps
and maintain a minimum terminal voltage of 10.5
volts at 27ÉC (80ÉF).TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp Bolt . . 135615 in.
lbs.
Battery Mount Fasteners....... 105610 in. lbs.
Fig. 18 Battery Tray Removal
1 ± BATTERY TRAY
2 ± LEFT STRUT TOWER
3 ± PDC
4 ± MOUNTING HOLES/SLOTS
5 ± COOLANT RESERVOIR
Load Test Cold
CrankingReserve
(Amps) Rating @
-18ÉC (0ÉF)Capacity
225 Amp 450 Amp 85 Minutes
PLBATTERY 8A - 11
REMOVAL AND INSTALLATION (Continued)

Connector
Name/NumberColor Location Fig.
Sunroof
Control
ModuleAt Sunroof N/S
Sunroof Motor At Sunroof N/S
Sunroof
SwitchBK At Switch N/S
Sunroof Vent
SwitchAt Switch N/S
Throttle
Position
SensorBK On Throttle
Body2
Torque
Converter
Clutch
Solenoid
(ATX)BK On
Transmission2
Traction
Control SwitchWT Center of
Instrument
Panel7Connector
Name/NumberColor Location Fig.
Trunk Key
Cylinder
SwitchGY On Decklid 17
Underhood
LampBK At Lamp N/S
Vehicle Speed
Control ServoBK At Right Front
Strut Tower1, 3
Vehicle Speed
SensorBK On
Transmission5
Windshield
Washer PumpRD At Right Front
Wheel
Opening1
Wipe/Wash
SwitchGY Center of
Instrument
Panel6
Wiper Motor BK Left Side of
Engine
CompartmentN/S
8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Right Tail/Stop
LampBK At Lamp 31
Seat Belt
SwitchBK Under Drivers
SeatN/S
Sentry Key
Immobilizer
ModuleBK Right Side of
Instrument
Panel25
Siren Left Front of
Vehicle18
Sunroof
Control
ModuleAt Sunroof N/S
Sunroof Motor At Sunroof N/S
Sunroof
SwitchBK At Switch N/S
Sunroof Vent
SwitchAt Switch N/S
Throttle
Position
SensorBK On Throttle
Body19
Torque
Converter
Clutch
Solenoid
(ATX)BK On
Transmission19Connector
Name/NumberColor Location Fig.
Traction
Control SwitchWT Center of
Instrument
Panel24
Trunk Key
Cylinder
SwitchGY On Decklid 36
Underhood
LampBK At Lamp N/S
Vehicle Speed
Control ServoBK At Left Front
Strut Tower19
Vehicle Speed
SensorBK On
Transmission22
Windshield
Washer PumpRD At Right Front
Wheel
Opening18
Wipe/Wash
SwitchGY Center of
Instrument
Panel25
Wiper Motor BK Right Side of
Engine
Compartment23
PL8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25
DESCRIPTION AND OPERATION (Continued)

2.0L SOHC ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION..................15
ENGINE COMPONENTS...................15
ENGINE LUBRICATION SYSTEM.............17
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE..........18
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING........18
FITTING PISTON RINGS...................19
FITTING CONNECTING RODS...............19
FITTING CRANKSHAFT BEARINGS...........19
CRANKSHAFT END PLAY..................20
REMOVAL AND INSTALLATION
TORQUE STRUTS........................20
ENGINE MOUNTÐLEFT...................21
ENGINE MOUNTÐRIGHT..................23
ENGINE MOUNT BRACKETÐRIGHT..........24
STRUCTURAL COLLAR....................25
ENGINE ASSEMBLY.......................25
INTAKE MANIFOLD.......................28
EXHAUST MANIFOLD.....................30
CYLINDER HEAD COVER..................31
SPARK PLUG TUBE SEALS.................32
SPARK PLUG TUBE.......................33
CAMSHAFT.............................33
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . . 34
VALVE SEALS AND SPRINGSÐIN VEHICLE....36
CYLINDER HEAD.........................37
CRANKSHAFT DAMPER...................40
TIMING BELT COVERS....................41TIMING BELT............................43
TIMING BELT TENSIONER..................46
CAMSHAFT OIL SEAL.....................46
OILPAN................................47
CRANKSHAFT OIL SEALÐFRONT............48
CRANKSHAFT OIL SEALÐREAR.............50
DRIVE PLATE...........................51
CRANKSHAFT...........................52
OIL FILTER ADAPTER.....................55
OILFILTER .............................55
OIL PUMP..............................55
PISTON AND CONNECTING ROD............57
DISASSEMBLY AND ASSEMBLY
OIL PUMP..............................60
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED............................60
CLEANING AND INSPECTION
INTAKE MANIFOLD.......................63
EXHAUST MANIFOLD.....................63
CYLINDER HEAD AND CAMSHAFT
JOURNALS............................63
OIL PUMP..............................64
CYLINDER BLOCK AND BORE..............65
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT......66
SPECIFICATIONS
2.0L SOHC ENGINE.......................68
TORQUE...............................71
SPECIAL TOOLS
2.0L SOHC ENGINE.......................72
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
left rear of the cylinder block bedplate (Fig. 1).
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEMBLY
A partial open deck is used for cooling and weight
reduction with water pump molded into the block.
Nominal wall thickness is 4 mm. The bedplate incor-
porates main bearing caps. The rear oil seal retainer
is integral with the block.
Fig. 1 Engine Identification 2.0L
1 ± ENGINE IDENTIFICATION LOCATION
PL2.0L SOHC ENGINE 9 - 15

CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 9).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front of its
travel and read the dial indicator. Refer to Engine
Specifications in this section for crankshaft specifica-
tions.
FEELER GAGE METHOD
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Donotloosen main bearing
cap.(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
REMOVAL AND INSTALLATION
TORQUE STRUTS
UPPER TORQUE STRUT
REMOVAL
(1) Remove bolts attaching strut to shock tower
bracket and engine mount bracket (Fig. 10).
(2) Remove the upper torque strut.
INSTALLATION
(1) Position the upper torque strut into mounting
locations.
(2) Install the mounting bolts and perform the
torque strut adjustment procedure.
LOWER TORQUE STRUT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right side splash shield.
(3) Remove bolts attaching lower strut to cross-
member and strut bracket (Fig. 10).
(4) Remove lower torque strut.
INSTALLATION
(1) Position lower torque strut into mounting loca-
tions.
(2) Install mounting bolts and perform torque
strut adjustment procedure.
(3) Install splash shield and lower vehicle
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.
(2) The engine position may now be adjusted by
positioning a suitable floor jack on the forward edge
of the transmission bell housing (Fig. 11).
NOTE: The floor jack must be positioned as shown
in (Fig. 11) to prevent minimal upward lifting of the
engine.
Fig. 8 Connecting Rod Side Clearance
Fig. 9 Checking Crankshaft End PlayÐ Dial
Indicator
9 - 20 2.0L SOHC ENGINEPL
SERVICE PROCEDURES (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)

(9) Install air cleaner assembly (Fig. 13).
(10) Lower vehicle.
ENGINE MOUNTÐRIGHT
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 upper and lower engine torque struts.
Refer to procedure in this section.
(4) Support engine with a suitable jack.
(5) Remove bolt access cover and bolt attaching
the right engine mount to mount bracket (Fig. 18).
(6) Remove engine mount bracket. Refer to proce-
dure in this section.
NOTE: The right engine mount attaching holes are
slightly oversize to compensate for manufacturing
tolerances. The mount has been set at the manufac-
turing plant for proper powertrain alignment. There-
fore, it is necessary to mark the position of the
mount before the attaching bolts are loosened.
(7) Using a permanent ink marker or equivalent,
mark the position of engine mount to the body frame
rail.
(8) Remove bolts attaching mount to body (Fig.
19).
(9) Remove mount between engine and body frame
rail. Mount removal may require engine position to
be raised or lowered to allow mount removal clear-
ance.
INSTALLATION
(1) Position mount into the original position on
body frame rail (Fig. 19).
Fig. 16 Left Mount (Automatic Transaxle)
1 ± MOUNT
2 ± TRANSAXLE
Fig. 17 Left Mount (Manual Transaxle)
1 ± MOUNT
2 ± TRANSAXLE
Fig. 18 Engine Mount To Bracket Bolt
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
PL2.0L SOHC ENGINE 9 - 23
REMOVAL AND INSTALLATION (Continued)

NOTE: Engine mount must be installed in the orig-
inal position on body frame rail. If mount was not
marked or frame rail was replaced, perform the fol-
lowing procedure.
(2) Perform the following procedure if mount posi-
tion was not previously marked or the frame rail was
replaced:
a. Insert new mount loosely in frame rail.
b. Align the four holes in the mount with the mat-
ing holes in the rail such that the holes are concen-
tric (frame rail holes centered in the mount holes).
c. Using a permanent ink marker or equivalent,
mark the position of engine mount to the body frame
rail while maintaining mounting hole concentricity.
(3) Ensure the mount maintains originally marked
position and install mount bolts. Tighten bolts to 28
N´m (250 in. lbs.) (Fig. 19).
(4) Install engine mount bracket. Refer to proce-
dure in this section.
(5) Install bolt attaching right engine mount to
bracket and tighten to 118 N´m (87 ft. lbs.) (Fig. 18).
(6) Remove support from under engine.
(7) Install upper and lower engine torque struts.
Refer to procedure in this section.
(8) Install crankshaft damper. Refer to procedure
in this section.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
ENGINE MOUNT BRACKETÐRIGHT
REMOVAL
(1) Remove upper and lower torque struts. Refer to
procedure in this section.(2) Remove power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(3) Support engine with a suitable jack.
(4) Remove engine mount through bolt access plug
(Fig. 20)
(5) Remove right engine mount to bracket through
bolt (Fig. 21).
(6) Remove engine mount bracket attaching bolts
(Fig. 22).
(7) Bracket removal requires engine to be raised
slightly to obtain engine-to-body clearance.
INSTALLATION
(1) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 22).
(2) Install bolt attaching engine mount to bracket
(Fig. 21). Tighten bolt to 118 N´m (87 ft. lbs.).
(3) Install mount bolt access plug (Fig. 20).
(4) Remove support from under engine.
(5) Install power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(6) Install upper and lower torque struts. Refer to
procedure in this section.
Fig. 19 Engine MountÐRight
1 ± SNUBBER PAD
2 ± RIGHT ENGINE MOUNT
3 ± BOLTS
Fig. 20 Engine Mount Bolt Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
9 - 24 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.NOTE: To remove transaxle dust cover, the front
bending strut must be removed.
(2) Remove structural collar from oil pan to tran-
saxle (Fig. 23).
INSTALLATION
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(1) Install the structural collar (Fig. 23) using the
following 3 step torque sequence:
²Step 1: Install the collar to oil pan bolts and
tighten to 3 N´m (30 in. lbs.).
²Step 2: Install collar to transaxle bolts and
tighten to 108 N´m (80 ft. lbs.).
²Step 3: Final torque the collar to oil pan bolts to
54 N´m (40 ft. lbs.).
(2) Lower vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect and remove battery and tray.
(3) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
Fig. 21 Engine Mount to Bracket
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
Fig. 22 Engine Mount Bracket Assembly
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET ASSEMBLY
Fig. 23 Structural CollarÐRemoval and Installation
1 ± OIL PAN
2 ± STRUCTURAL COLLAR
PL2.0L SOHC ENGINE 9 - 25
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)