1999 DODGE NEON Sprocket 85

CAMSHAFT OIL SEAL
REMOVAL
CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.
(1) Remove front timing belt cover, timing belt and
tensioner assembly. Refer to procedures outlined in
this section.
(2) Remove camshaft sprocket bolt, with the Mod-
ified Special Tool C-4687-1 as shown in (Fig. 36).
(3) Hold camshaft sprocket with modified tool
while removing bolt. Remove sprocket from camshaft.
(4) Remove rear timing belt cover.
(5) Remove camshaft seal using Special Tool
C-4679±A (Fig. 37).
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper if necessary.
INSTALLATION
(1) Install camshaft seal flush with cylinder head
using Special Tool MD 998306 (Fig. 38).
(2) Install rear timing belt cover.
(3) Install camshaft sprocket retaining bolt. Hold
camshaft sprocket with Special Tool C-4687-1 (Fig.
36) and tighten bolt to 115 N´m (85 ft. lbs.).(4) Install timing belt tensioner, timing belt, and
front cover. Refer to procedures outlined in this sec-
tion.
TIMING BELTÐWITH HYDRAULIC TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
²Remove the access plug from the outer timing
belt cover (Fig. 39).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 40).Fig. 36 Modification to Special Tool
Fig. 37 Removing Camshaft Oil Seal
Fig. 38 Installing Camshaft Seal
9 - 28 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

through the body and plunger to retain plunger in
place until tensioner is installed.
(4) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 48).
(5) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 49).
(6) Move crankshaft to 1/2 mark before TDC (Fig.
50) for belt installation.
(7) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.(8) Move crankshaft sprocket to TDC to take up
belt slack. Install tensioner to block but do not
tighten fasteners.
(9) Using a torque wrench on the tensioner pulley
apply 28 N´m (250 in. lbs.) of torque (Fig. 51).
(10) With torque being applied to the tensioner
pulley move the tensioner up against the tensioner
Fig. 46 Remove Timing Belt
Fig. 47 Compressing Timing Belt Tensioner
Fig. 48 Crankshaft Sprocket Timing
Fig. 49 Camshaft Timing Mark
Fig. 50 Adjusting Crankshaft Sprocket for Timing
Belt Installation
PL2.0L SOHC ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH MECHANICAL TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
²Remove the access plug from the outer timing
belt cover (Fig. 53).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 54).
REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 55).
Fig. 53 Timing Belt SystemÐWith Mechanical Tensioner
Fig. 54 Camshaft Timing Marks
Fig. 55 Right Inner Splash Shield
PL2.0L SOHC ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATIONÐ
SOHC ENGINE
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 60).
(2) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 60).
(3) Move crankshaft to 1/2 mark before TDC (Fig.
62) for belt installation.
(4) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.
(5) Move crankshaft sprocket to TDC to take up
belt slack.
(6) Remove the pin or 1/8º or 3 mm Allen wrench
from belt tensioner.
(7) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 63).
(8) Install front half of timing cover.
(9) Install engine mount bracket.
(10) Install power steering pump assembly and set
aside.
(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. 64).
(14) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(15) Raise vehicle on hoist and install right inner
splash shield.
(16) Lower vehicle and 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
Fig. 60 Crankshaft Sprocket Timing
Fig. 61 Camshaft Timing Mark
Fig. 62 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 63 Crankshaft and Camshaft Timing
PL2.0L SOHC ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)

(4) Install oil filter and adaptor.
(5) Install transaxle lower dust cover.
(6) Install powertrain bending strut.
(7) Install front engine mount and bracket.
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(8) Install the structural collar (Fig. 66) 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.).
(9) Fill engine crankcase with proper oil to correct
level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Using Special Tool 1026 and Insert 6827±A,
remove crankshaft damper (Fig. 68).
(2) Remove outer timing belt cover and timing
belt. Refer to procedure outlined in this section.(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 69).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 70). Do not damage the seal contact area
on the crankshaft.
INSTALLATION
(1) Install new seal by using Tool 6780±1 (Fig. 71).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket (Fig. 72). Using
Special Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing you.
(4) Install timing belt and covers. Refer to Timing
Belt System in this section for installation.
Fig. 67 Oil Pan Sealing
Fig. 68 Crankshaft DamperÐRemoval
Fig. 69 Crankshaft SprocketÐRemoval
Fig. 70 Front Crankshaft Oil SealÐRemoval
PL2.0L SOHC ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

(5) Install crankshaft damper (Fig. 73). Use thrust
bearing/washer and 12M-1.75 x 150 mm bolt from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.)
CRANKSHAFT OIL SEALÐREAR
REMOVAL
(1) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 74) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of thescrewdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 75).
Fig. 71 Front Crankshaft Oil SealÐInstallation
Fig. 72 Crankshaft SprocketÐInstallation
Fig. 73 Crankshaft DamperÐInstallation
Fig. 74 Rear Crankshaft Oil SealÐRemoval
9 - 38 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 75).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 76) until the tool bot-
toms out against the block (Fig. 77).
CRANKSHAFT
REMOVAL
(1) Remove oil filter and adapter from bedplate.
(2) Remove structural collar from oil pan to tran-
saxle housing.
(3) Remove oil pan.
(4) Remove crankshaft sprocket and oil pump both
procedures outlined in this section.
(5) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 78).
(6) Using a mallet tap the bedplate loose from the
engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.
(7) Bedplate should be removed evenly from the
cylinder block dowel pins.(8) Lift out crankshaft from cylinder block. Be sure
not to damage the main bearings or journals when
removing the crankshaft.
Fig. 75 Rear Crankshaft Seal and Special Tool
6926-1
Fig. 76 Crankshaft Seal Special Tool 6926-2
Fig. 77 Rear Crankshaft SealÐInstallation
PL2.0L SOHC ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)

(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)