1999 DODGE NEON check engine

(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed freely.(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 47).
(13) Install front half of timing cover.
(14) Install engine mount bracket.
(15) Install power steering pump assembly.
(16) Install right engine mount. Refer to procedure
outlined in this section.
(17) Remove jack from under engine.
(18) Install crankshaft damper using M12 1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 48).
(19) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(20) Raise vehicle on hoist and install right inner
splash shield.
(21) Lower vehicle and perform camshaft and
crankshaft timing relearn procedure as follows:
²Step 1: Connect 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.
²Step 2: Turn the ignition switch on and access
the ªmiscellaneousº screen.
²Step 3: Select re-learn cam/crank option and fol-
low directions on DRB screen.
Fig. 46 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 47 Adjusting Timing Belt Tension
Fig. 48 Crankshaft DamperÐInstallation
PL2.0L DOHC ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH MECHANICAL TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
(1) Remove number one spark plug.
(2) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(3) Remove the timing belt access cover from the
engine (Fig. 49).
(4) Check the timing marks on the camshaft
sprockets, they should align with each other (Fig.
50).
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotated after timing belt is removed. Damage to
valve components may occur. Always align timing
marks before removing timing belt.
(1) Remove accessory drive belts. Refer to Group
07, Cooling System for procedures.(2) Raise vehicle on hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Refer to
Crankshaft Damper procedure outlined in this sec-
tion.
(4) Lower vehicle.
(5) Support engine with a jack and remove right
engine mount. Refer to procedure outline in this sec-
tion.
(6) Remove power steering pump assembly and set
aside.
(7) Remove engine mount bracket and timing belt
cover fasteners, remove cover (Fig. 51).
Fig. 49 Timing Belt SystemÐDOHC With Mechanical Tensioner
Fig. 50 Camshaft Timing Check
Fig. 51 Front Timing Belt Cover
9 - 78 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Move crankshaft sprocket to TDC to take up
belt slack.
(6) Release the tensioner by removing the pin or
Allen wrench from the belt tensioner.
(7) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 56).
(8) Install front half of timing cover.
(9) Install engine mount bracket.
(10) Install power steering pump assembly.
(11) Install right engine mount. Refer to procedure
outlined in this section.
(12) Remove jack from under engine.
(13) Install crankshaft damper using M12 1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 57).
(14) Install accessory drive belts. Refer to Group
07, Cooling System for procedure.
(15) Raise vehicle on hoist and install right inner
splash shield.
(16) Lower vehicle and perform camshaft and
crankshaft timing relearn procedure as follows:
²Step 1: Connect 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.
²Step 2: Turn the ignition switch on and access
the ªmiscellaneousº screen.
²Step 3: Select re-learn cam/crank option and fol-
low directions on DRB screen.
TIMING BELT TENSIONERÐMECHANICAL
REMOVAL
(1) Remove timing belt. Refer to procedure out-
lined in this section.
(2) Remove tensioner assembly attaching bolts
(Fig. 58).
(3) Remove tensioner assembly.
CAUTION: The timing belt tensioner is serviced as
an assembly. To prevent premature timing belt fail-
ure and engine damage, DO NOT separate the ten-
sioner pulley from mounting bracket.
Fig. 56 Timing Mark Alignment
Fig. 57 Crankshaft DamperÐInstallation
Fig. 58 Timing Belt Tensioner AssemblyÐRemoval/
Installation
9 - 80 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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 inch). 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 pas-
sages.
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. 76). 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 inch), 0.032 mm (0.0012 inch), 0.250 mm
(0.010 inch). Never install an undersize bearing that
will reduce clearance below specifications.
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. 77).
(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 and O-ring in cylinder block.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartTorque Cure Gasket Maker to cylinder block
as shown in (Fig. 78).
(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 this bolts
down together until the bedplate contacts the cylin-
der block. Torque bolts to 30 N´m (22 ft. lbs.) (Fig.
79).
Fig. 76 Main Bearing IdentificationFig. 77 Installing Main Bearing Upper Shell
Fig. 78 Main Bearing Caps/Bedplate Sealing
9 - 86 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(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. 79).
(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 30 N´m (22 ft. lbs.) in
sequence shown in (Fig. 79).
(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) 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. 80).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 81)
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.).
Fig. 79 Main Bearing Caps/Bedplate Torque
Sequence
Fig. 80 Engine Oil Filter Adapter to Engine Block
Fig. 81 Engine Oil Filter
PL2.0L DOHC ENGINE 9 - 87
REMOVAL AND INSTALLATION (Continued)

Chart for specifications. Replace guides if they are
not within specification.
CHECK VALVE GUIDE HEIGHT
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 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. 97). 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 Compression Pressure: 246 ± 270 N
@ 38.0 mm (55 ± 60 lbs. @ 1.50 in.)
²Valve Open Compression Pressure: 549 ± 611 N
@ 29.25 mm (123 ± 137 lbs. @ 1.17 in.)
(2) Verify springs are not distorted with a steel
square and surface plate. Check springs from both
ends. Replace spring if the spring is more than 1.5
mm (1/16 inch) out of square.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 and a 45 1/2 degree angles.
(2) Inspect the remaining margin after the valves
are refaced (Fig. 98). Intake valves with less than 1.2
mm (3/64 inch.) margin and Exhaust valves with less
than 0.9 mm (1/32 inch.) margin should be discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for the
reseating stones. A true and complete surface must
be obtained.
(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.
Fig. 96 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide
DiameterIntake 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
ClearanceIntake 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.)
Valve Guide Height
Fig. 97 Testing Valve Spring
9 - 92 2.0L DOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Intake valve seat diameter is 34.37 - 34.63 mm
(1.353 - 1.363 inch.)
²Exhaust valve seat diameter is 29.37 29.63 mm
(1.156 1.166 inch.)
(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 serviced
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. For spec-
ification refer to Valve Specification Chart.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.90 to 1.30 mm
(0.035 to 0.051 inch.) (Fig. 99).
(8) Check valve tip height dimensions A after
grinding the valve seats or faces (Fig. 100). Grind
valve tip to 47.99 mm (1.889 in.) for exhaust valve
and 48.04 mm (1.891 in.) for intake valve when
installed in the head (Fig. 100). The valve tip cham-
fer may need to be reground to prevent seal damage
when the valve is installed.
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. 101). The valve stem
seals should be pushed firmly and squarely over
valve guide.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 44 1/2É
Head Diameter
Intake: 34.67 - 34.93 mm (1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm (1.195 - 1.205 in.)
Length (Overall)
Intake: 111.49 - 111.99 mm (4.389 - 4.409 in.)
Exhaust: 109.59 - 110.09 mm (4.314 - 4.334 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: 1.285 - 1.615 mm (0.050 - 0.063 in.)
Exhaust: 0.985 - 1.315 mm (0.038 - 0.051 in.)
Fig. 98 Refacing Intake and Exhaust Valves
Fig. 99 Refacing Valve Seats
Fig. 100 Checking Spring Installed Height and Valve
Tip Height Dimensions
PL2.0L DOHC ENGINE 9 - 93
DISASSEMBLY AND ASSEMBLY (Continued)

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 B after
refacing the valve and seat (Fig. 100). Make sure
measurements are taken from top of spring seat to
the bottom surface of spring retainer. If height is
greater than 38.75 mm (1.525 in.), install a 7.620
mm (0.030 inch.) spacer under the valve spring seat
to bring spring height back within specification.
(5) Install cam followers and camshaft as previ-
ously 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 or adjusters 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. 102).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 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.
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. 103). 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. 104), 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. 105).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 106). If measurement is 0.39
mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
Fig. 101 Valve Stem Oil Seal ToolFig. 102 Checking Cylinder Head Flatness
9 - 94 2.0L DOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)