1999 DODGE NEON Service Repair Manual

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 duct and air cleaner, dis-
connect all vacuum lines, electrical wiring and fuel
line from fuel rail and 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 from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to procedure outlined in
this section.
(12) Remove inner timing belt cover.
(13) Remove cylinder head cover.
(14) Remove camshaft and cam follower assem-
blies. Refer to Camshaft Service for removal proce-
dure outlined in this section.
(15) Remove cylinder head bolts.
CAUTION: Use only a plastic scraper to remove
gasket material on the aluminum head sealing sur-
faces to prevent damage to cylinder head.
CYLINDER HEAD FLATNESS
(1) Cylinder head must be flat within 0.1 mm
(0.004 inch) (Fig. 30).
NOTE: Inspect camshaft bearing journals for scor-
ing.
INSTALLATION
(1) Position new cylinder head gasket onto block.
(2) Before installing the bolts the threads should
be oiled with engine oil. The 4 short bolts 110 mm
(4.330 in.) are to be installed in positions 7, 8, 9, and
10 (Fig. 31).
(3) Tighten the cylinder head bolts in sequence
shown in (Fig. 31). Follow the four step procedure
listed below:
²Step 1: Bolts1±6to34N´m(25ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)²Step 2: Bolts1±6to68N´m(50ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)
²Step 3: Bolts1±6to68N´m(50ft.lbs.) and
bolts7±10to28N´m(20ft.lbs.)
²Step 4: Turn all bolts an additional 90É (1/4
turn).Do not use a torque wrench for this step.
(4) Install cam follower assemblies and camshafts.
Refer to procedure outlined in this section.
(5) Install cylinder head cover. Refer to procedure
outlined in this section.
(6) Install inner timing belt cover and camshaft
sprockets.
(7) Install timing belt tensioner and timing belt.
(8) Connect electrical connectors to cam sensor and
fuel injectors.
(9) Install coil pack and connect electrical connec-
tor.
(10) Install power steering pump.
(11) Connect power brake booster hose to intake
manifold.
(12) Install throttle linkage to throttle body.
(13) Connect all vacuum lines and electrical con-
nectors to throttle body.
Fig. 30 Checking Cylinder Head Flatness
Fig. 31 Cylinder Head Tightening Sequence
9 - 72 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(14) Connect fuel supply hose to fuel rail.
(15) Install air cleaner duct and air cleaner.
(16) Install accessory drive belts. Refer to Group
07, Cooling System for procedures.
(17) Raise vehicle and connect exhaust system to
exhaust manifold.
(18) Lower vehicle and connect negative cable to
battery.
(19) With DRB scan tool use ASD Fuel System
Test to pressurize fuel system. Check for fuel leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes, or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
(20) 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.
CRANKSHAFT DAMPER
NOTE: If a gap is found in the crankshaft damper,
in the area where the Poly-V Generator belt rides
this is normal and is acceptable (Fig. 32).
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 damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827±A (Fig. 34).
INSTALLATION
(1) 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. 35).
(2) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(3) Raise vehicle on hoist and install right inner
splash shield.
Fig. 32 Weld Gap
Fig. 33 Right Inner Splash Shield
Fig. 34 Crankshaft DamperÐRemoval
PL2.0L DOHC ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)

TIMING BELT COVER
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotated after timing belt is removed. Damage to
valve components may occur. Always align timing
marks before removing timing 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. 36).(3) Remove crankshaft damper bolt. Remove
damper using Special Tool 1026 and Insert 6827±A or
equivalent (Fig. 37).
(4) Lower vehicle and place a jack under engine
(5) Remove right engine mount. Refer to procedure
outlined in this section
(6) Remove right engine mount bracket (Fig. 38)
(7) Remove timing belt cover fasteners, remove
cover (Fig. 38).
INSTALLATION
(1) Install front timing cover.
(2) Install engine mount bracket.
(3) Install Right engine mount. Refer to procedure
outlined in this section for installation.
(4) Remove jack from under engine.
(5) Install crankshaft vibration damper Refer to
procedure outlined in this section for installation.
(6)
Install accessory drive belts. Refer to Group 7,
Cooling System, Accessory Drive section for procedure.
(7) Raise vehicle on hoist and install right inner
splash shield.
Fig. 35 Crankshaft DamperÐInstallation
Fig. 36 Right Inner Splash Shield
Fig. 37 Crankshaft DamperÐRemoval
Fig. 38 Front Timing Belt Cover
9 - 74 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH HYDRAULIC TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
(1) Remove number one spark plug.
(2) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(3) Remove the timing belt access cover from the
engine (Fig. 39).
(4) Check the timing marks on the camshaft
sprockets, they should align with each other (Fig.
40).
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotate after timing belt is removed. Damage to valve
components may occur. Always align timing marks
before removing timing belt.
(1) Remove accessory drive belts. Refer to Group
07, Cooling System for procedures.(2) Raise vehicle on hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Refer to
Crankshaft Damper procedure outlined in this sec-
tion.
(4) Lower vehicle.
(5) Support engine with a jack and remove right
engine mount. Refer to procedure outline in this sec-
tion.
(6) Remove power steering pump assembly and set
aside.
(7) Remove engine mount bracket and timing belt
cover fasteners, remove cover.
Fig. 39 Timing Belt SystemÐDOHC With Hydraulic Tensioner
Fig. 40 Camshaft Timing Check
Fig. 41 Front Timing Belt Cover
PL2.0L DOHC ENGINE 9 - 75
REMOVAL AND INSTALLATION (Continued)

(8) Align camshaft timing marks. Loosen timing
belt tensioner fasteners and remove timing belt.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 42).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
ÐDOHC ENGINE
(1) When tensioner is removed from the engine it
is necessary to compress the plunger into the ten-
sioner body.
(2) Place the tensioner into a vise and slowly com-
press the plunger (Fig. 43).
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
(3) When plunger is compressed into the tensioner
body install a pin 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. 44).
(5) Set camshafts timing marks together by align-
ing notches on sprockets (Fig. 45).
(6) Rotate crankshaft 1/2 tooth counterclockwise
from TDC (Fig. 46).
(7) Install timing belt in this direction. Starting at
the crankshaft, go around the water pump sprocket,
idler pulley, camshaft sprockets and then around the
tensioner pulley (Fig. 47).
(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 to tensioner
(Fig. 47).
(10) With torque being applied to the tensioner
pulley move the tensioner up against the tensioner
pulley bracket and tighten fasteners to 31 N´m (275
in. lbs.).
Fig. 42 Tensioner Pulley Assembly
Fig. 43 Compressing Timing Belt Tensioner
Fig. 44 Crankshaft Sprocket Timing
Fig. 45 Camshaft Timing Marks
9 - 76 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed freely.(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 47).
(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. 48).
(19) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(20) Raise vehicle on hoist and install right inner
splash shield.
(21) Lower vehicle and 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.
Fig. 46 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 47 Adjusting Timing Belt Tension
Fig. 48 Crankshaft DamperÐInstallation
PL2.0L DOHC ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)

TIMING BELTÐWITH MECHANICAL TENSIONER
CHECKING BELT TIMINGÐCOVER INSTALLED
(1) Remove number one spark plug.
(2) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(3) Remove the timing belt access cover from the
engine (Fig. 49).
(4) Check the timing marks on the camshaft
sprockets, they should align with each other (Fig.
50).
REMOVAL
CAUTION: Camshaft or crankshaft should not be
rotated after timing belt is removed. Damage to
valve components may occur. Always align timing
marks before removing timing belt.
(1) Remove accessory drive belts. Refer to Group
07, Cooling System for procedures.(2) Raise vehicle on hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Refer to
Crankshaft Damper procedure outlined in this sec-
tion.
(4) Lower vehicle.
(5) Support engine with a jack and remove right
engine mount. Refer to procedure outline in this sec-
tion.
(6) Remove power steering pump assembly and set
aside.
(7) Remove engine mount bracket and timing belt
cover fasteners, remove cover (Fig. 51).
Fig. 49 Timing Belt SystemÐDOHC With Mechanical Tensioner
Fig. 50 Camshaft Timing Check
Fig. 51 Front Timing Belt Cover
9 - 78 2.0L DOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft. Do not rotate the
camshaft once the timing belt has been removed as
damage to valve components may occur.
(8) Align camshaft timing marks and crankshaft
timing mark with arrow on oil pump housing (Fig.
52).
(9) Installa8mmAllen wrench into the timing
belt tensioner. Insert the long end of a 1/8º or 3 mm
Allen wrench into the pin hole on the front of the
tensioner.
(10) Rotate the tensioner counterclockwise with
the Allen wrench, while pushing in lightly on the 1/8º
or 3 mm Allen wrench, until it slides into the locking
hole.
(11) Remove timing belt.
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATIONÐ
DOHC 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. 53).
(2) Set camshafts timing marks together by align-
ing notches on sprockets (Fig. 54).
(3) Rotate crankshaft 1/2 tooth counterclockwise
from TDC (Fig. 55).
(4) Install timing belt in this direction. Starting at
the crankshaft, go around the water pump sprocket,idler pulley, camshaft sprockets and then around the
tensioner pulley (Fig. 56).
Fig. 52 Timing BeltÐRemoval
Fig. 53 Crankshaft Sprocket Timing
Fig. 54 Camshaft Timing Marks
Fig. 55 Adjusting Crankshaft Sprocket for Timing
Belt Installation
PL2.0L DOHC ENGINE 9 - 79
REMOVAL AND INSTALLATION (Continued)