1999 DODGE NEON cooling

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 into the cylin-
der head. The rocker shafts route oil to the rocker
arms/hydraulic lash adjuster assemblies.
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-
B LY:A 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
incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFT:A 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 trans-
mits crankshaft movement, via timing belt to the
camshaft sprocket providing timed valve actuation.
PISTONS:The SOHC EngineDOES NOThave
provision 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. Pistons And Connecting
rods are serviced as an assembly.
PISTON RINGS:The 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 consist of 2 steel rails and a expander
spacer.
CYLINDER HEADÐSOHC:It features a Single
Over Head Camshaft, four-valves per cylinder cross
flow design. The valves are arranged in two inlinebanks, with the two intake per cylinder facing
toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFTÐSOHC:The nodular iron camshaft
has five bearing journals and 3 cam lobes per cylin-
der. Provision for cam position sensor on the cam at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVESÐSOHC:Four valves per cylinder are
actuated by roller rocker arms/hydraulic lash adjust-
ers assemblies which pivot on rocker arm shafts. All
valves have 6 mm diameter chrome plated valve
stems. The valve train has 33 mm (1.299 inch) diam-
eter intake valves and 28 mm (1.10 inch) diameter
exhaust valves. Viton rubber valve stem seals are
integral with spring seats. Valve springs, spring
retainers, and locks are conventional design.
INTAKE MANIFOLD:The intake manifold is a
molded plastic composition, attached to the cylinder
head with ten fasteners. This long branch design
enhances low and mid-range torque.
EXHAUST MANIFOLD:The 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.
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. 3). The cylin-
der bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
9 - 14 2.0L SOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

(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. 14).
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. 14) 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.).
(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.
Fig. 12 Engine MountingÐRight
Fig. 13 Power Hop Damper
Fig. 14 Structural CollarÐRemoval and Installation
PL2.0L SOHC ENGINE 9 - 19
REMOVAL AND INSTALLATION (Continued)

(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. 15).
(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.
(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. 16). 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.
Fig. 15 Right Inner Splash Shield
Fig. 16 Positioning Engine Cradle Support Post
Mounts
9 - 20 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(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)

INSTALLATION
(1) Install valve seal/valve spring seat assembly
as outlined in the Valve Installation procedure in this
section.
(2) Using Special Tool MD-998772A compress valve
springs only enough to install locks. Correct align-
ment of tool is necessary to avoid nicking valve stems
(air pressure required), piston at TDC.
(3) Install rocker arm shaft assemblies as previ-
ously outlined in this section.
(4) Install cylinder head cover as previously out-
lined in this section.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System.
(3) Remove air cleaner inlet duct and air cleaner
(Fig. 30), disconnect all vacuum lines, electrical wir-
ing and fuel lines from throttle body.(4) Remove throttle linkage.
(5) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.
(8) Remove power steering pump assembly and set
aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and bracket from engine.
(10) Remove cylinder head cover.
(11) Remove cam sensor and fuel injectors wiring
connectors.
(12) Remove intake manifoldSOHC ONLY.
Removal procedure outline in Group 11.
(13) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(14) Remove rocker arm shaft assemblies.
(15) Remove cylinder head bolts.
Fig. 27 Removing and Installing Valve Spring
Fig. 28 Valve Stem Oil Seal Tool
Fig. 29 Valve Spring Assembly
Fig. 30 Air Cleaner Inlet Duct
PL2.0L SOHC ENGINE 9 - 25
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)

REMOVALÐTIMING BELT
(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. 41).
Fig. 39 Timing Belt SystemÐWith Hydraulic Tensioner
Fig. 40 Camshaft Timing Marks
Fig. 41 Right Inner Splash Shield
PL2.0L SOHC ENGINE 9 - 29
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)