1999 DODGE NEON check engine

(11) Install oil pump. If crankshaft end play is to
be checked refer to service procedures in this section.
(12) Install crankshaft sprocket.
(13) Install oil filter adapter and filter.
(14) Install oil pan and structural collar. Refer to
procedures outlined in the section.
(15) 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. 83).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 84)
avoid deforming the filter, install tool band strap
against the seam at the base of the filter. The seam,
joining the can to the base is reinforced by the
base plate.
(1) Turn counterclockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.(2) Remove Timing Belt. Refer to procedure in this
section.
(3) Remove Oil Pan. Refer to procedure in this sec-
tion.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 85).
(5) Remove oil pick-up tube.
(6) Remove oil pump (Fig. 86) and front crankshaft
seal.
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. 87). 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.
Fig. 83 Engine Oil Filter Adapter to Engine Block
Fig. 84 Engine Oil Filter
Fig. 85 Crankshaft SprocketÐRemoval
9 - 42 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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. 101).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 101) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 101).
(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. 102).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B or equivalent.
(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
(.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. 103). Refer to Valve Guide Specification
Chart for specifications. Replace guides if they are
not within specification.
(3) Check valve guide height (Fig. 104).
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
Fig. 101 Oil Pressure Relief Valve
Fig. 102 Oil Pump
Fig. 103 Checking Wear on Valve GuideÐTypical
PL2.0L SOHC ENGINE 9 - 47

33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and lift compress-
ing lever to set tone device (Fig. 105). Pull on torque
wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The Following specifications
apply to both intake and exhaust valve springs.
²Valve Closed Nominal ForceÐ 67 lbs. @ 39.8 mm
(1.57 in.)
²Valve Open Nominal ForceÐ 160 lbs. @ 32.6 mm
(1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.(2) Inspect the remaining margin after the valves
are refaced (Fig. 106). Intake valves with less than
0.95 mm (1/32 inch.) margin and Exhaust valves
with less than 1.05 mm (3/64 inch) margin should be
discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For valve specifications see Valve Specifica-
tion Chart.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
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.
²Intake valve seat diameter is 33 mm (1.299 in.)
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake Valve Exhaust Valve
5.975 - 6.000
mm (0.2352 -
0.2362 in.)5.975 - 6.000
mm (0.2352 -
0.2362 in.)
Valve Guide Clearance
Intake Valve Exhaust Valve
New: 0.023 - 0.066
mm (0.001 -
0.0025 in.)0.051 - 0.094
mm (0.002 -
0.0037 in.)
Service Limit: 0.25 mm (0.010 in.)
Fig. 104 Valve Guide Height
Fig. 105 Valve Spring Testing
Fig. 106 Intake and Exhaust Valve Refacing
9 - 48 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Exhaust valve seat diameter is 28 mm (1.102
in.)
(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 to 1.25 mm
(0.030 to 0.049 in.) (Fig. 107).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust
valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for
intake valve over spring seat when installed in thehead (Fig. 108). 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. 109). 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.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 45 1/2É
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 107 Valve Seat Refacing
Fig. 108 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
Fig. 109 Valve Stem Oil Seal Tool
PL2.0L SOHC ENGINE 9 - 49
DISASSEMBLY AND ASSEMBLY (Continued)

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 B after
refacing the valve and seat (Fig. 108). 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 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
CYLINDER HEAD AND CAMSHAFT JOURNALS
INSPECTING CYLINDER HEAD
Cylinder head must be flat within 0.1 mm (0.004
inch) (Fig. 110).
Inspect cylinder head camshaft bearings for wear.
Check 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 ifworn 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.
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not to gouge or scratch the alumi-
num head sealing surface.
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. 111). 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. 112), or if the diameter is 79.95
mm (3.148 inches) or less, replace outer rotor.
(4) If inner rotor measures 7.64 mm (.301 inch) or
less replace inner rotor (Fig. 113).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 114). If measurement is 0.39
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. 115) is .203
mm (.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 .102 mm (.004 inch) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 116).ONLYif rotors are in specs.
Fig. 110 Checking Cylinder Head Flatness
Fig. 111 Checking Oil Pump Cover Flatness
9 - 50 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(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 outlined in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
Fig. 112 Measuring Outer Rotor Thickness
Fig. 113 Measuring Inner Rotor Thickness
Fig. 114 Measuring Outer Rotor Clearance in
Housing
Fig. 115 Measuring Clearance Between Rotors
Fig. 116 Measuring Clearance Over Rotors
PL2.0L SOHC ENGINE 9 - 51
CLEANING AND INSPECTION (Continued)

CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 117). The cyl-
inder bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
inch) maximum. If the cylinder 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 maintained.Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 117). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart for specifications.
SPECIFICATIONS
2.0L SOHC
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)
Clearance 17.5 mm (11/16 in.) from bottom
of skirt. . . .0.012 - 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...............64mm(2.520 in.)
Piston Ring Groove Depth No. 1 .3.989 - 4.188 mm
(0.157 - 0.165 in.)
Piston Ring Groove Depth No. 2 .4.462 - 4.661 mm
(0.176 - 0.184 in.)
Piston Ring Groove DepthNo. 3 . .3.847 - 4.131 mm
(0.151 - 0.163 in.)
Pistons (Low Emission VehicleÐLEV)
Clearance 10.42 mm (0.42 in.) from bottom of
skirt......0.018 ± 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. 1 .3.989 - 4.188 mm
(0.157 - 0.165 in.)
Piston Ring Groove Depth No. 2 .4.462 - 4.661 mm
(0.176 - 0.184 in.)
Piston Ring Groove Depth No. 3 .3.847 - 4.131 mm
(0.151 - 0.163 in.)
Fig. 117 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Max. Out-of-
RoundMax. Taper
87.5 mm (3.445
in.)0.051 mm
(0.002 in.)0.051 mm
(0.002 in.)
Standard Piston Size
Federal
Emission:87.463 - 87.481 mm (3.4434 -
3.4441 in.)
Low Emmision
Vehicle (LEV):87.456 - 87.474 mm (3.4432 -
3.4439 in.)
Piston to Bore Clearance
Federal
Emission:0.012 - 0.044 mm (0.0005 - 0.0017
in.)
Low Emission
Vehicle (LEV):0.018 - 0.050 mm (0.0008 - 0.0020
in.)
Measurements taken at Piston Size Location.
9 - 52 2.0L SOHC ENGINEPL
CLEANING AND INSPECTION (Continued)

2.0L DOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 59
ENGINE IDENTIFICATION NUMBER......... 58
ENGINE LUBRICATION SYSTEM............ 58
GENERAL SPECIFICATION................ 58
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 60
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 63
CYLINDER BORE AND PISTON SIZING....... 60
FITTING CONNECTING RODS.............. 62
FITTING CRANKSHAFT BEARINGS.......... 62
FITTING PISTON RINGS.................. 61
REMOVAL AND INSTALLATION
CAMSHAFT OIL SEALS................... 81
CAM FOLLOWER AND HYDRAULIC LASH
ADJUSTER ASSEMBLY.................. 69
CAMSHAFT............................ 67
CRANKSHAFT DAMPER.................. 73
CRANKSHAFT OIL SEALÐFRONT........... 82
CRANKSHAFT OIL SEALÐREAR............ 83
CRANKSHAFT.......................... 85
CYLINDER HEAD COVER................. 67
CYLINDER HEAD........................ 71
ENGINE ASSEMBLY...................... 65
ENGINE MOUNTÐFRONT................. 63
ENGINE MOUNTÐLEFT................... 63
ENGINE MOUNTÐRIGHT................. 64OIL FILTER ADAPTER.................... 87
OILFILTER ............................ 87
OILPAN ............................... 81
OIL PUMP............................. 88
PISTON AND CONNECTING ROD........... 89
POWER HOP DAMPER................... 64
STRUCTURAL COLLARÐ2.0L.............. 64
TIMING BELT COVER.................... 74
TIMING BELT TENSIONERÐMECHANICAL.... 80
TIMING BELTÐWITH HYDRAULIC TENSIONER . 75
TIMING BELTÐWITH MECHANICAL
TENSIONER.......................... 78
VALVE SPRING AND SEALSÐ
CYLINDER HEAD NOT REMOVED......... 69
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................. 91
VALVE SERVICE WITH CYLINDER HEAD
REMOVED........................... 91
CLEANING AND INSPECTION
CYLINDER BLOCK AND BORE............. 96
CYLINDER HEAD AND CAMSHAFT JOURNALS . 94
OIL PUMP............................. 94
SPECIFICATIONS
2.0L DOHC............................. 96
TORQUE CHART 2.0L DOHC............... 98
SPECIAL TOOLS
2.0L DOHC............................. 98
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
GENERAL SPECIFICATION
Type ..............In-Line OHV, DOHC & SOHC
Bore......................87.5mm (3.445 Inch)
Stroke.....................83.0mm (3.268 inch)
Compression Ratio.....DOHC - 9.6:1 SOHC - 9.8:1
Displacement..........2.0 Liters (122 Cubic Inch)
Firing Order.........................1,3,4,2
Compression Pressure.1172 - 1551 kPa (170 - 225 psi)
Maximum Variation Between Cylinders.......25%
Lubrication. . . .Pressure Feed - Full Flow Filtration
(Crankshaft Driven Pump)
Engine Oil Capacity.Refer to Group 0, Lubrication and
Maintenance
ENGINE LUBRICATION SYSTEM
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow fil-
ter (Fig. 2) to the main oil gallery running the length
Fig. 1 Engine Identification DOHC
9 - 58 2.0L DOHC ENGINEPL