1999 DODGE NEON Service Repair Manual

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)

(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)

CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Mount dial indicator C-3339 or equivalent, to a
stationary point on cylinder head (Fig. 22).
(3) Using a suitable tool, move camshaft to rear-
ward limits of travel.
(4) Zero the dial indicator.
(5) Move camshaft forward to limits of travel and
read dial indicator.
(6) End play travel: 0.05 - 0.15 mm (0.002 - 0.06
in.).
INSTALLATION
NOTE: Check camshaft for binding in cylinder
head. Inspect camshaft bearing journals for dam-
age. If camshafts are binding, also check the cylin-
der head bearing surface for damage, and check
the camshaft bearing oil feed holes in the cylinder
head for clogging.Check the cam surface for abnormal wear and
damage, replace if defective. A visible worn groove
in the roller follower or on the cam lobes is cause
for replacement.
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate bearing journals and cam followers
with clean oil and install the camshafts. Install right
and left camshaft bearing caps #2 thru #5 and right
#6. Tighten M6 fasteners to 12 N´m (105 in. lbs.) in
sequence shown in (Fig. 23).
(2) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 24). Install bearing caps and
tighten M8 fasteners to 24 N´m (215 in. lbs.).
(3) Bearing cap number 1, must be installed before
the camshaft seals can be installed.
(4) Install rear timing cover, timing belt tensioner,
camshaft sprockets, timing belt, and front timing belt
covers. Refer to procedures outlined in this section.
Fig. 21 Camshaft Bearing CapÐRemoval
Fig. 22 Camshaft End Play
Fig. 23 Camshaft Bearing CapÐTightening
Sequence
Fig. 24 Camshaft Bearing Cap Sealing
9 - 68 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Install cylinder head cover using procedure out-
lined in this section.
(6) 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.
CAM FOLLOWER AND HYDRAULIC LASH
ADJUSTER ASSEMBLY
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, sprockets and covers using
procedure outlined in this section.
(3) Remove camshaft. Refer to procedure previ-
ously outline this section.
(4) Remove cam follower assemblies from cylinder
head. Keep the cam followers in the order they have
been removed from the head for reassembly. Mark
hydraulic lash adjusters for reassembly in their orig-
inal position. Lash adjusters are serviced as an
assembly.
NOTE: Inspect the cam follower assembly for wear
or damage (Fig. 25). Replace as necessary.
INSTALLATION
(1) Install hydraulic lash adjuster assembly mak-
ing sure that adjusters are at least partially full of
oil. This is indicated by little or no plunger travel
when the lash adjuster is compressed. Lubricate with
clean oil and install cam follower assemblies in their
original position on the hydraulic adjuster and valve
stem (Fig. 26).
(2) Install the camshafts. Refer to procedure previ-
ously outlined in this section.
HYDRAULIC LASH ADJUSTER NOISE
A tappet like noise may be produced from several
items. Refer to Lash Adjuster Noise Diagnosis in
Standard Service Procedures, outlined in this Group.
Hydraulic lash adjusters are replaced as an
assembly and are not repaired.
VALVE SPRING AND SEALSÐCYLINDER HEAD
NOT REMOVED
REMOVAL
(1) Remove camshafts as previously outlined in
this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90 - 120 psi air pressure.
(4) Using Special Tool MD998772A with adapter
6779 (Fig. 27) compress valve springs and remove
valve locks.
(5) Remove valve spring.
Fig. 25 Cam Follower Assembly
Fig. 26 Cam Follower AssembliesÐInstallation
Fig. 27 Removing and Installing Valve Spring
PL2.0L DOHC ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 28).
INSTALLATION
(1) Install valve seal/valve spring seat assembly
(Fig. 29) as outlined in the valve installation proce-
dure in this section.
(2) Install valve spring and retainer. Using Special
Tool MD998772A compress valve springs only enough
to install locks. Correct alignment of tool is necessary
to avoid nicking valve stems (air pressure required),
piston at TDC.
(3) Remove air hose and install spark plugs.
(4) Install camshafts as previously outlined in this
section.
(5) Install valve cover as previously outlined in
this section.
Fig. 28 Valve Stem Oil Seal ToolFig. 29 Valve Stem Seal and Valve Spring Seat
Assemblies
9 - 70 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD
CYLINDER HEAD AND VALVE ASSEMBLY
PL2.0L DOHC ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)