1999 DODGE NEON ignition

(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) 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.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Remove air cleaner inlet duct (Fig. 17)
(2) Remove ignition coil pack (Fig. 18).
(3) Remove the cylinder head cover bolts.
(4) Remove cylinder head cover from cylinder
head.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new cylinder head cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install cover assembly to head and tighten fas-
teners to 12 N´m (105 in. lbs.).
(3) Install ignition coil pack. Tighten fasteners to
23 N´m (200 in. lbs.).
SPARK PLUG TUBE
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 19). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
Fig. 17 Inlet Duct Removal
Fig. 18 Ignition Coil Pack
PL2.0L SOHC ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)

²Zero the dial indicator.
²Move camshaft forward to limits of travel and
read dial indicator.
²End play travel: 0.13 - 0.33 mm (0.005 - 0.013
in.).
(5) Install front camshaft seal. Camshaft must be
installed before the camshaft seal is installed. Refer
to procedure outlined in this section.
(6) Install cylinder head. Refer to procedure out-
lined in this section.
(7) Install rear timing belt cover.
(8) Install camshaft sprocket and tighten to 115
N´m (85 ft. lbs.).
(9) Install timing belt tensioner and timing belt.
Refer to procedures outlined in this section.
(10) Install rocker arm assemblies in correct order
as removed. Tighten the rocker arm assemblies in
sequence shown in (Fig. 22) to 28 N´m (250 in. lbs.).
(11) Install cylinder head cover and tighten fasten-
ers to 12 N´m (105 in. lbs.).
(12) Install ignition coil pack and ignition cables.(13) 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.
ROCKER ARM/HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Identify the rocker arm shaft assemblies before
removal.
(3) Loosen the attaching fasteners. Remove rocker
arm shaft assemblies from cylinder head.
(4) Identify the rocker arms spacers and retainers
for reassembly. Disassemble the rocker arm assem-
blies by removing the attaching bolts from the shaft
(Fig. 23).
(5) Slide the rocker arms and spacers off the shaft.
Keep the spacers and rocker arms in the same loca-
tion for reassembly.
Fig. 21 Camshaft End Play
Fig. 22 Rocker Arm Shaft Tightening Sequence
Fig. 23 Rocker Arm Shaft Assemblies
PL2.0L SOHC ENGINE 9 - 23
REMOVAL AND INSTALLATION (Continued)

For the rest of installation, reverse removal proce-
dure.
(3) 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.
TIMING BELT COVER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 33).
(3) Remove crankshaft vibration damper. Refer to
procedure outlined in this section for removal.
(4) Lower vehicle and place a jack under engine.
(5) Remove right engine mount. Refer to procedure
outlined in this section.
(6) Remove power steering pump assembly and set
aside.
(7) Remove right engine mount bracket (Fig. 34).
(8) Remove front timing belt cover (Fig. 35).
INSTALLATION
(1) Install front timing cover.
(2) Install engine mount bracket.
(3) Install power steering pump assembly.
(4) Install right engine mount. Refer to procedure
outlined in this section for installation.
(5) Remove jack from under engine.
(6) Install crankshaft vibration damper Refer to
procedure outlined in this section for installation.
(7) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(8) Raise vehicle on hoist and install right inner
splash shield.
Fig. 33 Right Inner Splash Shield
Fig. 34 Right Engine Mount Bracket
Fig. 35 Timing Belt Cover
PL2.0L SOHC ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)

pulley bracket and tighten fasteners to 31 N´m (275
in. lbs.) (Fig. 51).
(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed.
(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 51).
(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. 52).
(19) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(20) Raise vehicle on hoist and install right inner
splash shield.
(21) Lower vehicle and perform camshaft and
crankshaft timing relearn procedure as follows:
²Connect DRB scan tool to the data link (diagnos-
tic) connector. This connector is located in the pas-
senger 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.
Fig. 51 Adjusting Timing Belt Tension
Fig. 52 Crankshaft DamperÐInstallation
9 - 32 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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.
TIMING BELT TENSIONERÐMECHANICAL
REMOVAL
(1) Remove timing belt. Refer to procedure out-
lined in this section.
(2) Remove tensioner assembly attaching bolts
(Fig. 65).
(3) Remove tensioner assembly.
CAUTION: The timing belt tensioner is serviced as
an assembly. To prevent premature timing belt fail-
ure, DO NOT separate the tensioner pulley from
mounting bracket.
INSTALLATION
(1) Install timing belt tensioner assembly. Tighten
attaching bolts to 28 N´m (250 in. lbs.).
(2) Install timing belt. Refer to procedure outlined
in this section.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove front engine mount bracket. Refer to
Engine MountÐFront, in this section for procedures.
(3) Remove powertrain bending strut.
(4) Remove structural collar from oil pan to tran-
saxle (Fig. 66).
(5) Remove transaxle lower dust cover.
(6) If equipped with air conditioning remove oil fil-
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.(7) Remove oil pan.
(8) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 67).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
Fig. 64 Crankshaft DamperÐInstallationFig. 65 Timing Belt Tensioner AssemblyÐRemoval/
Installation
Fig. 66 Structural CollarÐRemoval and Installation
9 - 36 2.0L SOHC ENGINEPL
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)

(18) Lower vehicle. Remove air cleaner assembly.
(19) Remove power steering pump and reservoir,
Set them aside.
(20) Remove A/C compressor.
(21) Remove ground straps to body.
(22) Raise vehicle enough to allow engine dolly
and cradle Special Tools 6135 and 6710 to be
installed under vehicle.
(23) 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. 17). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(24) Install safety straps around the engine to cra-
dle tighten; straps and lock them into position.
(25) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(26) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(27) Remove engine and transmission mount thru-
bolts.
(28) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the cra-
dle to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Remove safety straps from engine and trans-
mission assembly. Slowly raise vehicle enough to
remove the engine dolly and cradle.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(8) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front engine mount. Refer to this sec-
tion for procedure.
(11) Manual transmission: Install power hop
damper.
(12) Install inner splash shield. Install wheels and
tires.
(13)Manual Transmission:Connect clutch cable
and linkages. Refer to Group 6, Manual Transaxle
Clutch.
(14)Automatic Transmission:Connect shifter
and kickdown linkage. Refer to Group 21, Transaxle
for procedures.
(15) Connect fuel line and heater hoses.
(16) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(17) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(18) Install radiator and shroud assembly. Install
radiator hoses. Fill cooling system. Refer to Group 7,
Cooling System for filling procedure.
(19) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(20) Install air cleaner and hoses.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) 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.
Fig. 17 Positioning Engine Cradle Support Post
Mounts
9 - 66 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Remove ignition coil pack (Fig. 18).
(2) Remove the cylinder head cover fasteners (Fig.
19).
(3) Remove cylinder head cover from cylinder
head.
COVER INSTALLATION
NOTE: Before installation, clean cylinder head and
cover mating surfaces. Make certain the rails are
flat.
(1) Install new cylinder head cover gaskets.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.(2) Apply Mopar Silicone Rubber Adhesive Sealant
at the camshaft cap corners and at the top edges of
the 1/2 round seal.
(3) Install cylinder head cover assembly to head
and tighten fasteners in sequence shown in (Fig. 19).
Using the 3 step torque method:
²Step 1 Tighten all fasteners to 4.5 N´m (40 in.
lbs.)
²Step 2 Tighten all fasteners to 9.0 N´m (80 in.
lbs.)
²Step 3 Tighten all fasteners to 12 N´m (105 in.
lbs.)
(4) Install ignition coil pack. Tighten fasteners to
12 N´m (105 in. lbs.).
CAMSHAFT
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, timing belt tensioner, cam-
shaft sprockets, and timing belt covers. Refer to pro-
cedures outlined in this section.
(3) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 20).
(4) Loosen the camshaft bearing cap attaching fas-
teners in sequence shown in (Fig. 21); one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(5) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
Fig. 18 Ignition Coil Pack
Fig. 19 Cylinder Head Cover and Gasket
Fig. 20 Camshaft Bearing Cap Identification
PL2.0L DOHC ENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)