1999 DODGE NEON dimensions

REAR SUSPENSION
INDEX
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GENERAL INFORMATION
GENERAL INFORMATION................. 39
DESCRIPTION AND OPERATION
COIL SPRING........................... 41
COMPETITION PACKAGE SUSPENSION...... 41
KNUCKLE............................. 41
LATERAL LINKS AND TENSION STRUTS...... 41
REAR SUSPENSION..................... 39
STABILIZER BAR........................ 41
STRUT................................ 41
DIAGNOSIS AND TESTING
KNUCKLE............................. 42
LATERAL LINKS......................... 42
STABILIZER BAR AND BUSHINGS........... 43
STABILIZER BAR ATTACHING LINKS......... 43
STRUT INSPECTION (ON VEHICLE)......... 42
TENSION STRUT........................ 42
SERVICE PROCEDURES
REAR WHEEL ALIGNMENT................ 43REMOVAL AND INSTALLATION
COIL SPRING........................... 44
KNUCKLE............................. 46
LATERAL LINKS......................... 48
STABILIZER BAR........................ 45
STRUT ASSEMBLY...................... 43
DISASSEMBLY AND ASSEMBLY
STABILIZER BAR BUSHINGS............... 53
STRUT ASSEMBLY...................... 50
ADJUSTMENTS
STRUT ADJUSTMENT COMPETITION
PACKAGE SUSPENSION................ 53
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIFICATIONS...................... 54
SPECIAL TOOLS
REAR SUSPENSION..................... 54
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: Only frame contact or wheel lift hoisting
equipment can be used on vehicles having a fully
independent rear suspension. Vehicles with inde-
pendent rear suspension can not be hoisted using
equipment designed to lift a vehicle by the rear
axle. If this type of hoisting equipment is used dam-
age to rear suspension components will occur.
NOTE: If a rear suspension component becomes
bent, damaged or fails, no attempt should be made
to straighten or repair it. Always replace with a new
component.
DESCRIPTION AND OPERATION
REAR SUSPENSION
The rear suspension system used on this vehicle is
a fully independent type rear suspension system (Fig.
1).A forged rear knuckle is bolted to each rear strut.
The movement of the rear knuckle is controlled lat-
erally using lateral links going from the front and
rear of the knuckle to the rear crossmember. Fore
and aft movement of the knuckle is controlled by a
tension strut.
The lateral links and tension strut have rubber iso-
lator bushings at each end. The lateral links are
attached to the rear crossmember and knuckle, using
a common bolt and nut assembly at each end. The
tension strut bolts to the bottom of the knuckle and
to a bracket attached to the floor pan of the vehicle.
The lateral links, tension strut and spindle are
normally replaced only when the part has been dam-
aged or when the vehicle has been involved in an
accident. If a suspension part has been damaged, be
sure to check the underbody dimensions of the car. If
the underbody dimensions are not correct, the frame
of the vehicle must be straightened, before replace-
ment suspension components are installed.
PLSUSPENSION 2 - 39

a unique bolt and nut assembly at each end. The lat-
eral arm to rear crossmember attaching bolts are
longer than the lateral arm to knuckle attaching
bolts. Each lateral arm to knuckle attaching bolt and
nut assembly uses 2 flat washers. Each lateral arm
to rear crossmember attaching bolt uses 1 flat
washer and 1 adjustment cam to provide a means for
rear wheel Toe adjustment. The tension strut assem-
bly attaches to a bracket on the frame rail and to the
bottom of the knuckle.
Lateral arms, tension struts and knuckles are nor-
mally replaced only when the part has been damaged
or when the vehicle has been involved in an accident.
If a suspension part has been damaged, be sure to
check the underbody dimensions of the car. If under-
body dimensions of the vehicle are not correct, the
frame must be straightened before replacement sus-
pension components are installed.
DIAGNOSIS AND TESTING
STRUT INSPECTION (ON VEHICLE)
(1) Inspect for damaged or broken coil springs
(Fig. 4).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 4).
(3) Inspect for damaged lower spring isolator (Fig.
4).
(4) Lift dust boot and inspect strut assembly for
evidence of fluid running from the upper end of fluid
reservoir. (Actual leakage will be a stream of fluid
running down the side and dripping off lower end ofunit). A slight amount of seepage between the strut
rod and strut shaft seal is not unusual and does not
affect performance of the strut assembly (Fig. 5). Also
inspect jounce bumpers for signs of damage or dete-
rioration.
KNUCKLE
The rear knuckle is not a repairable component of
the rear suspension. If it is determined that the
knuckle is cracked, bent or broken when servicing
the vehicle, no attempt is to be made to repair or to
straighten the knuckle.THE KNUCKLE MUST BE
REPLACED IF FOUND TO BE DAMAGED IN
ANY WAY.
LATERAL LINKS
Inspect the lateral link isolator bushings and
sleeves for signs of damage or deterioration. If the
lateral link isolator bushings or sleeves are damaged
or are deteriorated, replacement of the lateral link
assembly will be required. The isolator bushings are
not serviceable as a separate component of the lat-
eral link assembly.
Inspect the lateral links for signs of contact with
the ground or road debris which has bent or caused
other damage to the lateral link assembly. If the lat-
eral link is bent or damaged, the lateral link will
require replacement.Do not attempt to repair or
straighten a lateral link.
TENSION STRUT
Inspect the tension strut bushings and retainers
for signs of deterioration or damage. If the tension
strut bushings are deteriorated or the retainers are
damaged, replacement of the tension strut bushings
and or the retainers will be required. The bushings
and retainers are serviceable as separate components
of the tension strut.
Fig. 4 On Vehicle Strut Assembly Inspection
Fig. 5 Strut Assembly Leakage Inspection
2 - 42 SUSPENSIONPL
DESCRIPTION AND OPERATION (Continued)

The major difference between the two engines is
component location which affects the ignition system
service procedures. There are various sensors that
are in different locations due to a different cylinder
head and intake manifold.
The 2.0L engines use a fixed ignition timing sys-
tem. The distributorless electronic ignition system is
referred to as the Direct Ignition System (DIS).
Basic ignition timing is not adjustable.The
Powertrain Control Module (PCM) determines spark
advance. The system's three main components are
the coil pack, crankshaft position sensor, and cam-
shaft position sensor.
POWERTRAIN CONTROL MODULE
The Powertrain Control Module (PCM) controls the
ignition system (Fig. 1). The PCM supplies battery
voltage to the ignition coil through the Auto Shut-
down (ASD) Relay. The PCM also controls the ground
circuit for the ignition coil. By switching the ground
path for the coil on and off, the PCM adjusts ignition
timing to meet changing engine operating conditions.
During the crank-start period the PCM maintains
spark advance at 9É BTDC. During engine operation
the following inputs determine the amount of spark
advance provided by the PCM.
²Intake air temperature
²Coolant temperature
²Engine RPM
²Intake manifold vacuum
²Knock sensor
The PCM also regulates the fuel injection system.
Refer to the Fuel Injection sections of Group 14.
SPARK PLUGS
The 2.0L engines uses resistor spark plugs. For
spark plug identification and specifications, Refer to
the Specifications section at the end of this group.Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group 0.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. After
cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the
electrodes (Fig. 2) to the dimensions specified in the
chart at the end of this section.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion and damage.
Tighten spark plugs to 28 N´m (20 ft. lbs.) torque.
SPARK PLUG CABLES
Spark plug cables are sometimes referred to as sec-
ondary ignition wires. The wires transfer electrical
current from the coil pack to individual spark plugs
at each cylinder. The resistor type, nonmetallic spark
plug cables provide suppression of radio frequency
emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil and spark plugs. Terminals should
be fully seated. The nipples and spark plug covers
should be in good condition. Nipples should fit tightly
on the coil. Spark plug boot should completely cover
the spark plug hole in the cylinder head cover. Install
the boot until the terminal snaps over the spark
plug. A snap must be felt to ensure the spark plug
cable terminal engaged the spark plug.
Loose cable connections will corrode, increase resis-
tance and permit water to enter the coil towers.
These conditions can cause ignition malfunction.
Fig. 1 Powertrain Control Module
Fig. 2 Setting Spark Plug Electrode Gap
8D - 2 IGNITION SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

²Exhaust valve seat diameter is 28 mm (1.102
in.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. The intake valve seat must be ser-
viced when the valve seat width is 2.0 mm (0.079 in.)
or greater. The exhaust valve seat must be serviced
when the valve seat width is 2.5 mm (0.098 in.) or
greater. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.75 to 1.25 mm
(0.030 to 0.049 in.) (Fig. 107).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust
valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for
intake valve over spring seat when installed in thehead (Fig. 108). The valve tip chamfer may need to
be reground to prevent seal damage when the valve
is installed.
CLEANING
Clean all valve guides, valves and valve spring
assemblies thoroughly with suitable cleaning solution
before reassembling.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 109). The valve stem
seals should be pushed firmly and squarely over
valve guide.
CAUTION: If oversize valves are used, there is only
one oversize valve available. The same stem seal is
used on both the standard and oversize valve.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 45 1/2É
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 107 Valve Seat Refacing
Fig. 108 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
Fig. 109 Valve Stem Oil Seal Tool
PL2.0L SOHC ENGINE 9 - 49
DISASSEMBLY AND ASSEMBLY (Continued)

²Intake valve seat diameter is 34.37 - 34.63 mm
(1.353 - 1.363 inch.)
²Exhaust valve seat diameter is 29.37 29.63 mm
(1.156 1.166 inch.)
(6)
Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. The intake valve seat must be serviced
when the valve seat width is 2.0 mm (0.079 in.) or
greater. The exhaust valve seat must be serviced when
the valve seat width is 2.5 mm (0.098 in.) or greater.
Otherwise the cylinder head must be replaced. For spec-
ification refer to Valve Specification Chart.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.90 to 1.30 mm
(0.035 to 0.051 inch.) (Fig. 99).
(8) Check valve tip height dimensions A after
grinding the valve seats or faces (Fig. 100). Grind
valve tip to 47.99 mm (1.889 in.) for exhaust valve
and 48.04 mm (1.891 in.) for intake valve when
installed in the head (Fig. 100). The valve tip cham-
fer may need to be reground to prevent seal damage
when the valve is installed.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 101). The valve stem
seals should be pushed firmly and squarely over
valve guide.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 44 1/2É
Head Diameter
Intake: 34.67 - 34.93 mm (1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm (1.195 - 1.205 in.)
Length (Overall)
Intake: 111.49 - 111.99 mm (4.389 - 4.409 in.)
Exhaust: 109.59 - 110.09 mm (4.314 - 4.334 in)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.285 - 1.615 mm (0.050 - 0.063 in.)
Exhaust: 0.985 - 1.315 mm (0.038 - 0.051 in.)
Fig. 98 Refacing Intake and Exhaust Valves
Fig. 99 Refacing Valve Seats
Fig. 100 Checking Spring Installed Height and Valve
Tip Height Dimensions
PL2.0L DOHC ENGINE 9 - 93
DISASSEMBLY AND ASSEMBLY (Continued)

FRAMES
INDEX
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REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER....... 3
SPECIFICATIONS
STRUCTURAL DIMENSIONS................ 4TORQUE SPECIFICATIONS................ 10
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER
WARNING: IF SUSPENSION CROSSMEMBER IS
REPLACED DUE TO COLLISION DAMAGE, INSPECT
THE STEERING COLUMN TO STEERING GEAR
COUPLING FOR DAMAGE. REFER TO GROUP 19,
STEERING FOR INSTRUCTIONS.
Before removing front suspension crossmem-
ber, index mark location of crossmember on
frame to aid installation.
The front suspension crossmember must be prop-
erly installed to achieve design camber, caster set-
tings and wheel stagger. The crossmember can be
installed out of position on the frame rails due to its
design. Bolts and cage nuts hold the rear of the
crossmember to the frame torque boxes. Bolts and
J-nuts hold the front of the crossmember to the
frame rails. No designed in locating device is used to
position the crossmember in the vehicle. Before
removing the crossmember mark the frame torque
box around the rear mounting location to aid instal-
lation. A crossmember that is removed during service
must be installed in the same position from which it
was removed. To verify that crossmember is in the
proper position, refer to the dimensions provided.
Front end dimensions are gauged from the principal
locating point (PLP) holes located under the frame
torque boxes rearward of the front wheels. After
removal and installation of the crossmember is per-
formed, verify that front suspension alignment is
within specifications. If camber, caster settings and
wheel stagger is not within specifications, loosen and
reposition crossmember to bring suspension within
specifications. Refer to Group 2, Front Suspension
and Driveshaft for additional information.
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Using a suitable marking device, mark the out-
line of the suspension crossmember on the frame
torque box around the rear mounting location.(3) Remove front wheels from vehicle.
(4) Remove pinch bolts holding front ball joints to
spindles.
(5) Separate ball joints from spindles.
(6) Position a suitable lifting device under the
crossmember.
(7) Remove bolts holding suspension crossmember
to frame rails above lower control arms (Fig. 1).
(8) Remove bolts holding crossmember to frame
torque boxes and allow front of crossmember to
swing down.
(9) Remove bolts holding steering gear to cross-
member.
(10) Separate steering gear from crossmember.
(11) Tie steering gear to a suitable structure above
to support gear after crossmember is removed.
(12) Separate front suspension crossmember from
vehicle.
INSTALLATION
If a new crossmember is to be installed, transfer
stabilizer bar and lower control arms from original
crossmember. Refer to Group 2, Suspension and
Driveshaft for proper procedures.
(1) Place front suspension crossmember in position
on vehicle.
(2) Remove tie device supporting steering gear.
Fig. 1 Front Suspension Crossmember
PLFRAME AND BUMPERS 13 - 3

(3) Place steering gear in position on crossmember.
(4) Install bolts to hold steering gear to crossmem-
ber.
(5) Position lifting device under the crossmember.
(6) Lift crossmember to frame rails.
(7) Engage bolts to hold crossmember rear mounts
into cage nuts in the frame torque boxes. Do not
tighten bolts.
(8) Install bolts to hold crossmember to frame rails
above lower control arms.
(9) Lower and remove lifting device.
(10) Align crossmember to index marks. Verify
that crossmember is at the specified dimensions from
the PLPs (Fig. 2).
(11) Tighten bolts to hold suspension crossmember
to frame rails and torque boxes.
(12) Insert ball joints into spindles.
(13) Install pinch bolts to hold front ball joints to
spindles.(14) Install front wheels on vehicle.
(15) Lower vehicle and verify front suspension
alignment. If camber, caster settings and wheel stag-
ger is not within specifications, loosen and reposition
crossmember to bring suspension within specifica-
tions. Refer to Group 2, Front Suspension and Drive-
shaft for additional information.
SPECIFICATIONS
STRUCTURAL DIMENSIONS
Structural dimensions are listed in metric mea-
surements. All dimensions are from center to center
of Principal Locating Point (PLP), or from center to
center of PLP and fastener location (Fig. 3), (Fig. 4),
(Fig. 5), (Fig. 6), (Fig. 7), and (Fig. 8).
Fig. 2 Forward Frame and Suspension Crossmember
13 - 4 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

To remove the differential bearing cup from the
extension housing/adapter side, use Special Tool
6062A, Remover. To install the differential bearing
cup on the extension housing/adapter side, use Spe-
cial Tool 6536, Driver and Special Tool C-4171, Han-
dle.
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
CLEANING AND INSPECTION
VALVE BODY
Allow all parts to soak a few minutes in a suitable
clean solvent. Wash thoroughly and blow dry with
compressed air. Be sure all passages are clean and
free from obstructions.
Inspect manual and throttle valve operating levers
and shafts for being bent, worn or loose. If a lever is
loose on its shaft, it should be replaced. Do not
attempt to straighten bent levers.
Inspect all mating surfaces for burrs, nicks and
scratches. Minor blemishes may be removed with cro-
cus cloth, using only a very light pressure. Using a
straightedge, inspect all mating surfaces for warpage
or distortion. Slight distortion may be corrected,
using a surface plate. Be sure all metering holes in
steel plate are open. Using a penlight, inspect bores
in valve body for scores, scratches, pits, and irregu-
larities.
Inspect all valve springs for distortion and col-
lapsed coils. Inspect all valves and plugs for burrs,
nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is
taken not to round off sharp edges. The sharpness of
these edges is vitally important. It prevents foreign
matter from lodging between valve and valve body.
This reduces the possibility of sticking. Inspect all
valves and plugs for freedom of operation in valve
body bores.
When bores, valves, and plugs are clean and dry,
the valves and plugs should fall freely in the bores.
The valve body bores do not change their dimensions
with use. Therefore, a valve body that was function-
ing properly when vehicle was new, will operate cor-
rectly if it is properly and thoroughly cleaned. There
is no need to replace a valve body unless it is dam-
aged in handling.
ADJUSTMENTS
GEARSHIFT CABLE
Normal operation of the Park/Neutral Position
Switch provides a quick check to confirm proper link-
age adjustment.
Move the selector level slowly forward until it
clicks into the PARK (P) position. The starter should
operate.
After checking the (P) position, move selector
slowly toward the NEUTRAL (N) position until lever
drops in the (N) position. If the starter will operate
also at this point, the gearshift linkage is properly
adjusted. If the starter fails to operate in either posi-
tion, linkage adjustment is required.
Fig. 194 Remove Bearing Cup
Fig. 195 Install Bearing Cup
PLTRANSAXLE 21 - 99
DISASSEMBLY AND ASSEMBLY (Continued)