1999 DODGE NEON engine oil

Piston Pins
Clearance in Piston. . . .0.008 - 0.020 mm (0.0003 -
0.0008 in.)
In Rod (Interference) . . .0.018 - 0.043 mm (0.0007 -
0.0017 in.)
Diameter .20.998 - 21.003 mm (0.8267 - 0.8269 in.)
End Play.............................None
Length.......74.75 - 75.25 mm (2.943 - 2.963 in.)
Piston Rings
Ring Gap Top Compression Ring . . .0.23 - 0.52 mm
(0.009 - 0.020 in.)
Ring Gap 2nd Compression Ring . . .0.49 - 0.78 mm
(0.019 - 0.031 in.)
Ring Gap Oil Control (Steel Rails). .0.23 - 0.66 mm
(0.009 - 0.026 in.)
Ring Side Clearance Both Compression
Rings......0.025 - 0.065 mm (0.0010 - 0.0026 in.)
Oil Ring (Pack) .0.004 - 0.178 mm (0.0002 - 0.0070
in.)
Ring Width Compression Rings. . . .1.17 - 1.19 mm
(0.046 - 0.047 in.)
Oil Ring (Pack) . .2.854 - 3.008 mm (0.1124 - 0.1184
in.)
Connecting Rod
Bearing Clearance......0.026 - 0.059 mm (0.001 -
0.0023 in.)
Piston Pin Bore Diameter......20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter. . . .50.991 - 51.005 mm
(2.0075 - 2.0081 in.)
Side Clearance . .0.13 - 0.38 mm (0.005 - 0.015 in.)
Total Weight (Less Bearing) . .543 grams (1.20 lbs.)
Crankshaft
Connecting Rod Journal Diameter......47.9924 -
48.0076 mm (1.8894 - 1.8900 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Main Bearing Diametrical Clearance
No.1-5 ...0.022 - 0.062 mm (0.0008 - 0.0024 in.)
End Play.....0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter . .51.9924 - 52.0076 mm (2.0469 - 2.0475
in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Rocker Arm Shaft
Rocker Arm Shaft Diameter . . .19.996 ± 19.984mm
(0.786 ± 0.7867 in.)
Rocker Arm Shaft Retainers (Width)
Intake (All)................28.46 mm (1.12 in.)
Exhaust....1 & 5 29.20 mm (1.14in.) 2, 3, and 4 -
40.45 mm (1.59 in.)
Rocker Arm/Hydraulic Lash Adjuster *
Rocker Arm Inside Diameter. . . .20.00 ± 20.02 mm
(0.787 ± 0.788 in.)Rocker Arm Shaft Clearance. . . .0.016 ± 0.054 mm
(0.0006 ± 0.0021 in.)
Body Diameter.....22.949 ± 22.962 mm (0.9035 ±
0.9040 in.)
Plunger Travel Minimum (Dry) .2.2 mm (0.087 in.)
Rocker Arm Ratio....................1.4 to 1
Cylinder Head Camshaft Bearing Diameter
No.1 .....41.20 ± 41.221 mm (1.622 ± 1.6228 in.)
No.2 .......41.6 ± 41.621 mm (1.637 ± 1.638 in.)
No.3 .......42.0 ± 42.021 mm (1.653 ± 1.654 in.)
No.4 .......42.4 ± 42.421 mm (1.669 ± 1.670 in.)
No.5 ......42.8 ± 42.821 mm (1.685 ± 1.6858 in.)
Camshaft Journal Diameter
No. 1 . . . .41.128 ± 41.147 mm (1.619 ± 1.6199 in.)
No.2 .....41.528 ± 41.547 mm (1.634 ± 1.635 in.)
No.3 .....41.928 ± 41.947 mm (1.650 ± 1.651 in.)
No.4 .....42.328 ± 42.374 mm (1.666 ± 1.668 in.)
No. 5 . . . .42.728 ± 42.747 mm (1.682 ± 1.6829 in.)
Diametrical Bearing Clearance . .0.053 ± 0.093 mm
(0.0027 ± 0.003 in.)
Max. Allowable............0.12 mm (0.0047 in.)
End Play...........0.05 ± 0.39 mm (0.0059 in.)
Lift (Zero Lash )
Intake.....................7.2 mm (0.283 in.)
Exhaust..................7.03 mm (0.277 in.)
Valve Timing Exhaust Valve**
Closes (ATDC)..........................5.4É
Opens (BBDC).........................43.7É
Duration............................229.1É
Valve Timing Intake Valve **
Closes (ABDC)........................41.1É
Opens (ATDC).........................13.9É
Duration............................207.2É
Valve Overlap...........................0É
Cylinder Head
Material....................Cast Aluminum
Gasket Thickness (Compressed) . . .1.15 mm (0.045
in.)
Valve Seat
Angle.................................45É
Runout (Max.)...............0.050 mm (0.002)
Width (Finish) Intake and Exhaust. . . .0.75 ± 1.25
mm (0.030 ± 0.049 in.)
Valve Guide Finished
Diameter I.D. . .5.975 ± 6.000 mm (.235 ± .236 in.)
Guide Bore Diameter (Std.)......11.0±11.02 mm
(0.4330 ± 0.4338 in.)
Valves
Face Angle Intake and Exhaust......45±45-1/2É
Head Diameter Intake . .32.12 ± 33.37 mm (1.303 ±
1.313 in.)
Head Diameter Exhaust . .28.57 ± 28.83 mm (1.124
± 1.135 in.)
PL2.0L SOHC ENGINE 9 - 53
SPECIFICATIONS (Continued)

Valve Margin
Intake......1.15 ± 1.48 mm (0.0452 ± 0.0582 in.)
Exhaust.....1.475 ± 1.805 mm (0.058 ± 0.071 in.)
Valve Length (Overall)
Intake.....114.69 ± 115.19 mm (4.515 ± 4.535 in.)
Exhaust . . .109.59 ± 110.09 mm (4.603 ± 4.623 in.)
Valve Stem Tip Height
Intake........45.01 ± 46.07 mm (1.77 ± 1.81 in.)
Exhaust.......43.51 ± 44.57 mm (1.71 ± 1.75 in.)
Stem Diameter
Intake......5.934 ± 5.952 mm (0.234 ± 0.234 in.)
Exhaust.....5.906 ± 5.924 mm (0.233 ± 0.233 in.)
Stem to Guide Clearance
Intake. . . .0.048 ± 0.066 mm (0.0018 ± 0.0025 in.)
Exhaust . .0.0736 ± 0.094 mm (0.0029 ± 0.0037 in.)
Max. Allowable Intake......0.076 mm (0.003 in.)
Max. Allowable Exhaust.....0.101 mm (0.004 in.)
Valve Springs
Free Length (Approx.).......44.4 mm (1.747 in.)
Nominal Force (Valve closed) . .91 N´m @ 39.8 mm
(67 ft. lbs. @ 1.57 in.)
Nominal Force (Valve open). . .239 N´m @ 32.6 mm
(176 lbs. @ 1.28 in.)
Installed Height...........40.18 mm (1.580 in.)
* SERVICE AS AN ASSEMBLY WITH ROCKER
ARM.
** ALL READINGS IN CRANKSHAFT DEGREES,
AT 0.5 mm (0.019 in.) OF VALVE LIFT.
TORQUE CHART 2.0L SOHC
DESCRIPTION TORQUE
Camshaft Sensor Pick Up
Bolts....................9.6 N´m (85 in. lbs.)
Camshaft Sprocket
Bolt.....................115N´m(85ft.lbs.)
Connecting Rod Cap
Bolts..........27N´m(20ft.lbs.) Plus 1/4 Turn
CollarÐOil Pan to Transaxle
Step 1: Collar to Oil Pan Bolts . .3 N´m (30 in. lbs.)
Step 2: Collar to Transaxle Bolts.108 N´m (80 ft. lbs.)
Step 3: Collar to Oil Pan Bolts .54 N´m (40 ft. lbs.)
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts...........30N´m(22ft.lbs.)
M11 Main Cap Bolts.........81N´m(60ft.lbs.)
Crankshaft Damper
Bolt....................142 N´m (105 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)
Drive Plate to Flywheel
Bolts.....................95N´m(70ft.lbs.)
Engine Mount BracketÐRight
Bolts.....................61N´m(45ft.lbs.)DESCRIPTION TORQUE
Engine Mounting
Bolts........Refer to Engine Mount Installation
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................12N´m(105 in. lbs.)
Front Mount Torque Bracket
Bolts.....................33N´m(24ft.lbs.)
Front Powertrain Bending Strut
Long Bolts................101 N´m (75 ft. lbs.)
Short Bolt.................61N´m(45ft.lbs.)
Intake Manifold
Bolts....................12N´m(105 in. lbs.)
Oil Filter Adapter
Fastener..................80N´m(60ft.lbs.)
Oil Filter..................20N´m(15ft.lbs.)
Oil Pan
Bolts....................12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .41 N´m (30 ft. lbs.)
Rear Torque BracketÐ2.0L Engine
Bolts w/Auto. Transaxle......110N´m(80ft.lbs.)
Bolts w/Manual Transaxle.....61N´m(45ft.lbs.)
Rocker Arm Shaft
Bolts....................28N´m(250 in. lbs.)
Spark Plugs................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Cover
Bolts M6.................12N´m(105 in. lbs.)
Timing Belt Tensioner AssemblyÐMechanical
Bolts....................28N´m(250 in. lbs.)
Timing Belt TensionerÐHydraulic
Pulley Bolt.................68N´m(50ft.lbs.)
Pivot Bracket Bolt...........31N´m(23ft.lbs.)
Tensioner Bolts.............31N´m(23ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
9 - 54 2.0L SOHC ENGINEPL
SPECIFICATIONS (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

of the cylinder block. A cylinder head restrictor,
located in the block, provides increased oil flow to the
main oil gallery (Fig. 3).MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylin-
der head bolt to an oil gallery running the length of
the cylinder head. The camshaft journals are par-
tially slotted to allow a predetermined amount of
pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam-
shaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
BLYA 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
Fig. 2 Engine Lubrication Components
Fig. 3 Engine Lubrication System ÐDOHC Engine
PL2.0L DOHC ENGINE 9 - 59
DESCRIPTION AND OPERATION (Continued)

incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFTA nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 52 mm diameter
main and 48 mm diameter crank pin journals (all)
have undercut fillet radiuses that are deep rolled for
added strength. To optimize bearing loading 8 coun-
terweights are used. Hydrodynamic seals provide end
sealing, where the crankshaft exits the block.
Anaerobic gasket material is used for parting line
sealing. A sintered iron timing belt sprocket is
mounted on the crankshaft nose. This sprocket pro-
vides motive power; via timing belt to the camshaft
sprocket providing timed valve actuation.
PISTONSThe DOHC EngineDO NOThave pro-
vision for a free wheeling valve train. Non free
wheeling valve train means, in the event of a broken
timing belt Pistons will contact the Valves. All
engines use pressed-in piston pins to attach forged
powdered metal connecting rods. The connecting rods
are a cracked cap design and are not repairable. Hex
head cap screw are used to provide alignment and
durability in the assembly.
PISTON RINGSThe piston rings include a
molybdenum faced top ring for reliable compression
sealing and a taper faced intermediate ring for addi-
tional cylinder pressure control. Oil Control Ring
Package contains of 2 steel rails and a expander
spacer.
CYLINDER HEADFeatures a Dual Over Head
Camshaft (DOHC), 4 valves per cylinder cross flow
design. The valves are arranged in two in-line banks,
with the ports of the bank of two intake valves per
cylinder facing toward the radiator side of engine
and ports of the bank of two exhaust valves per cyl-
inder facing toward the dash panel. Incorporates
powder metal valve guides and seats. Integral oil gal-
leys within the cylinder head supplies oil to the
hydraulic lash adjusters, camshaft and valve mecha-
nisms.
CAMSHAFTSThe nodular iron camshafts have
six bearing journals and 2 cam lobes per cylinder.
Flanges at the rear journals control camshaft end
play. Provision for cam position sensor is located on
the intake camshaft at the rear of cylinder head. A
hydrodynamic oil seal is used for oil control at the
front of the camshaft.
VA LV E SFour valves per cylinder are actuated by
roller cam followers which pivot on stationary
hydraulic lash adjusters. All valves have 6 mm diam-
eter chrome plated valve stems. The valve sizes are
34.8 mm (1.370 inch.) diameter intake valves and
30.5 mm (1.20 inch.) diameter exhaust valves. Viton
rubber valve stem seals are integral with the springseats. Valve springs, spring retainers, and locks are
conventional.
INTAKE MANIFOLDThe intake manifold is a
two piece aluminum casting, attached to the cylinder
head with ten fasteners. This long branch fan design
enhances low and mid-speed torque.
EXHAUST MANIFOLDThe exhaust manifold is
made of nodular cast iron for strength and high tem-
peratures. Exhaust gasses exit through a machined,
articulated joint connection to the exhaust pipe.
COMPONENT REPLACEMENT
If any of the following parts have been changed or
replaced:
²Camshaft
²Camshaft Position Sensor
²Camshaft Position Sensor Target Magnet
²Cylinder Block
²Cylinder Head
²Water Pump
²Powertrain Control Module (PCM)
²Timing Belt and Timing Belt Tensioner
The camshaft and crankshaft timing relearn proce-
dure must be performed. Refer to the component
Removal and Installation procedure outlined in this
Group.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 4). The cylin-
der 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
9 - 60 2.0L DOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

(2) Check piston ring to groove side clearance (Fig.
7). Refer to Piston Ring Specification Chart.
FITTING CONNECTING RODS
(1) Follow the procedure specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance (Fig. 8). Refer to Connecting Rod Specification
Chart for specifications.
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
NOTE: The rod bearing bolts should not be reused.(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 9). Refer to Connecting Rod Specifica-
tion Chart for specifications.
FITTING CRANKSHAFT BEARINGS
Refer to Measuring Main Bearing Clearance in
Standard Service Procedures. Refer to Crankshaft
Specification Chart for specifications.
Fig. 7 Piston Ring Side Clearance
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Ring Gap Wear
LimitGroove Clearance Maximum Groove
Clearance
Upper Ring 0.23 - 0.52 mm
(0.009 - 0.020 in.)0.8 mm (0.031 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.49 - 0.78 mm
(0.019 - 0.031 in.)1.0 mm (0.039 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.23 - 0.66 mm
(0.009 - 0.026 in.)1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate After
Assembly
Fig. 8 Connecting Rod Bearing Clearance
Fig. 9 Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.026 - 0.059 mm (0.001 - 0.0023
in.)
Wear Limit: 0.075 mm (0.003 in.)
Connecting Rod Side Clearance
New Part: 0.13 - 0.38 mm (0.005 - 0.015 in.)
Wear Limit: 0.40 mm (0.016 in.)
9 - 62 2.0L DOHC ENGINEPL
SERVICE PROCEDURES (Continued)

ENGINE MOUNTÐRIGHT
(1) Remove the purge duty solenoid from engine
mount bracket.
(2) Remove the right engine mount insulator verti-
cal fasteners from frame rail (Fig. 13).
(3) Remove the load on the engine mounts by care-
fully supporting the engine and transmission assem-
bly with a floor jack.(4) Remove the thru-bolt access hole cover. Remove
the thru-bolt from the insulator assembly (Fig. 13).
Remove insulator.
(5) Reverse removal procedure for installation.
Tighten engine mount to rail fasteners to 54 N´m (40
ft. lbs.), then tighten engine mount to engine bracket
thru-bolt to 108 N´m (80 ft. lbs.).
POWER HOP DAMPER
NOTE: Power hop damper is used on manual trans-
mission vehicle only.
(1) Remove the thru-bolt and nut from the front
suspension crossmember (Fig. 14).
(2) Remove the damper nut and grommets.
Remove the damper.
(3) Remove the power hop damper bracket, if nec-
essary.
(4) Reverse removal procedure for installation.
Tighten all bolts and nuts to 54 N´m (40 ft. lbs.)
STRUCTURAL COLLARÐ2.0L
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. 15).
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. 15) using the
following 3 step torque sequence:
Fig. 11 Engine MountingÐFront
Fig. 12 Engine MountingÐLeft
Fig. 13 Engine MountingÐRight
9 - 64 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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. Set
Powertrain Control Module (PCM) aside.
(3) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(4) Remove upper radiator hose, radiator and fan
module. Refer to Group 7, Cooling System for proce-
dure.
(5) Remove lower radiator hose.
(6) Disconnect automatic transmission cooler lines
and plug. If equipped.
(7) Disconnect clutch cable (Manual) and transmis-
sion shift linkage.
(8) Disconnect throttle body linkage.
(9) Disconnect engine wiring harness.
(10) Disconnect heater hoses.
(11) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(12) Hoist vehicle and remove right inner splash
shield (Fig. 16).
(13) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(14) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(15) Disconnect exhaust pipe from manifold.
(16) Remove front engine mount.
(17) Manual transmission: Remove power hop
damper.
Fig. 14 Power Hop Damper
Fig. 15 Structural CollarÐRemoval and Installation
Fig. 16 Right Inner Splash Shield
PL2.0L DOHC ENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)